DAVIS-BOURNONVIIXE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


WORKROOM EXERCISES 


DAV1S.BOORNONVIIXE WELDING INSTITUTE 




























































DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

ADJUSTING THE FLAME AND 
HANDLING THE TORCH 


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DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 400 





Copyright 1919 by the Davis-Bournonvili.e Co. 


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MAY 28 1319 


Adjusting the Flame and Handling the Torch 

The members of the welding class should be dressed suitably 
in overalls and jumpers, or wear leather aprons. Each man should 
be provided with suitable colored spectacles, which should 
be adjusted to fit before entering the workroom. 



NEUTRAL, OXIDIZING AND CARBONIZING TORCH FLAMES 


The equipment at each station should comprise a No. 616 
Davis-Bournonville welding torch ; eight tips, Nos. 1 to 8 in¬ 
clusive ; oxygen and acetylene gas regulators, with pressure 
gauges; spark lighter; tip wrench; pliers; four firebricks; and a 
supply of 16-gauge steel plates, each 6 inches long, and 1 % inch 































wide. A 16-gauge plate is about 1/16 inch thick. The No. 2 tip 
should be in the torch. 

1. Take position at stations, and check up equipment. 

2. Adjust the firebricks to the proper level for the individual. 
(The test is to compare the top of the firebricks with the elbow 
when the forearm is held horizontal. The operator should turn 
his back to the bricks with his forearm extended and apply the 
point of the elbow). 

3. Place a 16-gauge plate across the firebrick, letting about 
yX inch at each end rest on the bricks. 

4. Take the torch in the right hand, (Left-handed workers 
should take the torch in the left hand). 

5. Hold the torch with the tip down over the steel plate on 
the firebricks and stand in approved position. Work the torch 
back and forth holding the tip about inch from the plate. 
Practice doing this for a few moments in order to become familiar 
with the hang of the torch and the motion. 

6. Identify the oxygen and acetylene hose and their re¬ 
spective valves and regulators. (The oxygen hose is black and the 
acetylene is red.) 

7. Open the oxygen needle valve in the torch handle with 
the right hand. (The oxygen needle valve is the upper valve.) 

8. Open the oxygen cylinder valve (or pipe line service 
valve) very slowly. Open it fully. Use the left hand. 

9. Adjust the oxygen gas regulator until the working pres¬ 
sure gauge shows 4 pounds pressure. Turn the regulator screw 
handle clockwise, slowly. 

10. Close the oxygen needle valve. (The upper valve in 
the torch handle.) 

11. Open the acetylene needle valve. (The lower valve in 
the torch handle.) 

12. Open the acetylene cylinder valve (or pipe-line service 
valve) slowly. Open it fully. 

13. Adjust the gas regulator working pressure to 2 pounds, 
and light the gas quickly with the spark lighter. (Do this as 
quickly as possible to avoid filling the room with acetylene gas.) 

14. Open the oxygen needle valve a little way. 


15. Note the appearance of the oxy-acetylene flame, as fol¬ 
lows : 

16. A white cone appears at the tip, and beyond the cone 
there is a white envelope of flame not so hot. The streamer is a 
long blue flame. Combustion is unbalanced; there is insufficient 
oxygen and excess carbon in the flame. Prove it thus: 

17. Apply the flame to the piece of 16-gauge steel, holding 
the point of the white cone close to the metal. The metal melts, 
and then begins to boil and appear cloudy. This shows that car¬ 
bon is entering the molten steel. Do not prolong the experiment 
or the metal will burn. 

Note: —When the molten metal is cold the surface will be 
pitted and will have a mottled appearance. The part that was 
melted will be brittle. 

18. Now open the oxygen needle valve full and note the 
flame appearance. 

19. The white hot cone at the tip is very short. It is sur¬ 
rounded by a blue white envelope. It bums spitefully, and roars. 
Combustion is unbalanced because of excess oxygen. The oxygen 
combines with all the fuel or acetylene gas available, and the re¬ 
mainder tends to attack the metal. The flame is an oxidizing 
flame. Prove it, thus: 

20. Apply the flame to the steel plate, holding the torch so 
that the point of the white hot cone is close to the metal. The 
metal melts and sparks. A white foam forms on the surface. 
Sparking and' foaming show that the metal is oxidizing. 

Note: —The molten metal when cold is shiny, and has little 
strength because it contains oxidized steel. 

21. Close the oxygen valve slightly until combustion in the 
flame is balanced. Two distinct cones will become visible. The 
cone next to the tip is white hot; beyond it is a long blue cone, 
also very hot The sound of the flame differs from that of the 
carbonizing and oxidizing flames. It is the neutral flame which 
neither carbonizes nor oxidizes the metal. Prove it, thus: 

22. Apply to the steel plate as before, and melt a puddle. The 
molten metal lies quiet beneath the flame. It is clean and clear. 
It flows like syrup, and few sparks are produced. A weld made 


with the neutral flame will be free from carbonized and oxidized 
metal. But do not hold the flame too long in one place. 

23. Repeat the torch adjustment's for carbonizing, oxidizing 
and neutral flames, and the tests on the steel plates. 

24. Close the oxygen needle valve. 

25. Close the acetylene needle valve. 

2G. Close the acetylene cylinder or pipe-line service valve. 

27. Close the oxygen cylinder valve or pipe-line service 
valve. 

28. Open the oxygen needle valve, in the torch handle. 

29. Turn the oxygen pressure regulator screw counter¬ 
clockwise until it is free. 

30. Open the acetylene needle valve in torch. 

31. Turn the acetylene pressure regulator screw counter¬ 
clockwise until it is free. 

32. Close both needle valves. 

33. Hang up the torch. 

34. Dismiss. 

Questions 

1. Why should the oxy-acetvlene welder always wear 
colored glasses? 

2. What number tip is used in the torch for this exercise? 

3. Why are firebricks used to support the steel plates to be 
welded ? 

4. What is the reason for holding the torch with the tip 
down when lighting? 

5. Why are the oxygen hose and acetylene hose different 
colors? 

6. Which is the oxygen needle valve in the torch handle? 

7. Why should the cylinder stop valves be opened as far as 
possible. 

> 

8. What is the effect of a carbonizing flame on steel? 

9. How do you know when the flame is oxidizing? 

10. What is the puddle? 

11. What is the order of turning on the gases and lighting 
the torch? 

12. What is the order of shutting down? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

U 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

h~ Y A 

3 

6 

8.1 

u 

9.3 

a 

4 


4 

8 

12.5 

a 

14.3 

u 

5 

H~T6 

5 

10 

17.8 

u 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

u 

7 


6 

14 

33.2 

u 

37.9 

a 

8 

H~ 5 A 

6 

16 

42.0 

u 

47.9 

u 

9 

5 A~H 

6 

18 

58.0 

u 

65.9 

u 

10 

/d~up 

6 

20 

82.5 

u 

94.0 

a 

11 

( Extra] 

8 

22 

89.0 

a 

101.2 

a 

12 

t Heavy/ 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 
























DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 16 -GAUGE 
STEEL PLATES 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 401 




Butt Welding 1 6-Gauge Steel Plates 

The workroom equipment at the stations should be the same 

as in the workroom exercise “Adjusting the Flame and Handling 
the Torch.” 

1. Select two thin steel plates about 6 inches long, 1J4 
inches wide and 1/16 inch thick. 

2. Lay the plates sidd by side close together, bridging 
across the firebricks so that about *4 inch of the plates at each 
end rests on the bricks. 

3. Take the torch in the right hand, holding the tip down. 
Practice movement. 



4. Turn on the gases; adjust the pressure regulators to 
supply oxygen at 4 pounds pressure and acetylene at 2 pounds 
pressure. Light the gas quickly. 

5. Adjust the torch needle valves for the neutral flame. 

6. Tack the left end' of the steel plates together. This is 
done by holding the torch flame close to the plates until the metal 
melts and runs together. 

7. Play the torch back and forth across the joint for a few 
moments to heat the plates. 










































8. Hold the torch with the head inclined to the right and 
the tip pointing to the left. The torch head should stand at an 
angle of about 50 degrees with the plates in the line of the joint. 
The tip should be held at 90 degrees in the plane at right angles 
to the joint. 

9. Start to weld at the right end, working from right to 

left. 

10. Hold' the torch so that the tip of the white hot cone of 
flame is about % inch from the metal. 

11. Shorten the movements of the torch across the joint 
until the metal melts and forms a puddle of molten metal in the 
joint. 

12. As soon as the puddle forms in the joint begin to move 
the torch towards the left, continuing the short zig-zag movement. 

13. Keep the torch in motion, but do not move to the left 
along the joint faster than the puddle advances. 

14. Learn to hold the torch easily. Do not grasp the torch 
firmly. Grasping it firmly tires the muscles and makes the arm 
tremble. Learn to work it easily. 

15. Give the torch a uniform motion, but govern the rate 
of movement to the left by the puddle. You cannot weld without 
melting the steel. 

16. When the end of the joint is reached lift the torch 
quickly to avoid' making a hole in the weld at the end of the plates. 

17. Pick up the welded plates with the pliers, and examine 
Note if the weld “penetrates” clear through to the other side, that 
is, see if the weld is sound clear through. 

Caution: Always use the pliers to handle the work, and 
avoid burns. 

18. Lay the welded plate to one side, and select two more 
and repeat the operation of welding. 

19. Shut off the gases as directed in the exercise “Adjust¬ 
ing the Flame and Handling the Torch.” 

20. Hang up the torch. 

21. Dismiss. 

Common Defects of First Welds 

Welds uneven. Caused by moving torch along the joint 


1 . 


too fast and too slow. Movement not uniform or in step with 
puddle. 

2. Fused portion of plate not in joint but at one side. 
Caused' by not playing the torch over the joint equally on each 
side. 

3. Holes in joint. Caused by holding frame too long in 
one place. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

I Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 


1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

U 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

A-Ks 

3 

6 

8.1 

u 

9.3 

a 

4 

Vs~% 

4 

8 

12.5 

a 

14.3 

u 

5 


5 

10 

17.8 

a 

21.3 

u 

6 


6 

12 

25.0 

a 

28.5 

a 

/ 

■h- l A 

6 

14 

33.2 

a 

37.9 

u 

8 

V2-% 

6 

16 

42.0 

a 

47.9 

u 

9 


6 

18 

58.0 

a 

65.9 

u 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

\ Heavy/ 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 14-GAUGE 
STEEL PLATES WITH ADDING 

MATERIAL 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 402 




Butt Welding 1 4-Gauge Steel Plates, with Adding 

Material 

Station equipments in the. work-room are the same as in 
the exercise “Adjusting the Flame and Handling the Torch”, but 
adding material in the shape of 1/16 inch welding wire is sup¬ 
plied; also some 14-gauge plates, same dimensions otherwise 
as the 16-gauge plates, are supplied. The No. 3 tip should 



BUTT WELDING STEEL PLATES WITH ADDING MATERIAL 


be in the torch. The No. 3 tip requires an oxygen gas pressure 
of 6 to 7 pounds and an acetylene pressure of 3 pounds. 

1. Select two 14-gauge steel plates and lay them close side 
by side across the firebricks. 

2. Turn on the gases, and' adjust the oxygen regulator for 
a working pressure of 6 pounds, and the acetylene regulator for 






































working pressure of 3 pounds. (Higher .pressures are required 
than in the previous exercises, because the No. 3 tip is used in 
the torch instead of the No. 2 tip.) 

3. Light the gas quickly. 

4. Adjust for neutral flame. Take a welding wire in the 
left hand. Heat the wire at a point 4 inches from the end 
and bend around to stand at right angles with the part held in the 
left hand. 

5. Tack the left end of the plates together, using the weld¬ 
ing rod or wire. 

6. Tack at the right end also using the welding rod. 

7. Start to weld, working from right to left. 

8. Hold the torch head at an angle of about 50 degrees 
with the plates, in the line of the joint, and at 90 degrees in the 
other plane. 

9. Hold the welding rod in the opposite way at an angle 
of about 45 degrees with the plates. 

10. The welding rod must be held close to the plate so that 
the lower end touches the puddle. 

11. Move the torch back and forth across the joint in a zig¬ 
zag. Be sure the movement is equal each side of the joint. 

12. Move the welding rod back and forth across the joint 
also, but not so far. 

13. Do not direct the flame against the welding rod; the 
welding rod must be melted by the puddle. 

14. Add no more welding material than required. The 
reason for using welding rod is to fill the joint and avoid making 
the welded part thinner than the remainder of the plate. 

15. Continue welding until the end of the plate is reached. 

16. Shut oflf the oxy-acetylene gas by closing the oxygen 
needle valve. (The upper valve in the handle.) 

17. Close the acetylene needle valve. (The lower valve in 
the handle.) 

18. Hang up the torch. 

19. Pick up the welded plate with the pliers and examine 
the weld. Turn it over and see if the weld has “penetrated 
uniformly”—if the plate is welded clear through. 

20. Lay the welded piece aside and repeat the operation on 


two more plates. 

21. Shut off gases as directed in the exercise “Adjusting the 
Flame and Handling the Torch”. 

22. Dismiss. 

Common Defects of First Welds with Adding 

Material 

1. Welds uneven. Caused by lack of uniform motion of 
torch along joint and across it. 

2. Welds ragged. Caused by uneven application of weld¬ 
ing material too much in one place and too little in another. 

3. Welds shiny and scaly. Caused by torch flame being too 
long in one place. This will oxidize the steel even though the 
flame is neutral. 

4. Penetration poor. Caused by fusing the metal on the 
surface only and not letting the heat sink in. 

5. Holes in welds. Caused by holding flame still in one 
place too long. Always keep torch in motion. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

Wight/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

u 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

(6 

5.5 

u 

3 

T2-VS 

3 

6 

8.1 

U 

9.3 

u 

4 

Vs-H 

4 

8 

12.5 

u 

14.3 

a 

5 

H-TS 

5 

10 

17.8 

a 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

u 

7 


6 

14 

33.2 

u 

37.9 

u 

8 


6 

16 

42.0 

a 

47.9 

u 

9 

Vs-Vt 

6 

18 

58.0 

a 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

( Extra) 

8 

22 

89.0 

u 

101.2 

a 

12 

Heavy/ 

8 

24 

114.5 

« 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING L’S OF 16-GAUGE 

STEEL 


DAVIS-BOURNONVILLE INSTITUTE 

JEI5SEY CITY, N. J. 


Form 403 




Welding L’s of 1 6-Gauge Steel 

The station equipment in the workroom is the same as for 
the exercise “Adjusting the Flame and Handling the Torch”. This 
exercise is welding the corner of two 16-gauge plates set at 
right angles to form an L. 

1. Adjust the firebricks as directed in the exercise “Adjust- 
to form an L, the corner being up. 



CORNER WELDING STEEL PLATES WITHOUT ADDING MATERIAL 


2. Adjust the regulators for the No. 2 tip, turn on the gases 
and light. 

3. Tack the plates together at each end. 

4. Start welding at the right end using no adding material. 

5. Move the torch back and forth across the joint. Make 




















sure that that the edges of the plates are fused and the puddle 
started before advancing the torch along the joint. 

6. Hold the torch in one place no longer than necessary 
to form the puddle. Holding the torch too long in one place wastes 
gas, injures the metal and may melt a hole in the joint. 

7. Be very careful to manipulate the torch, so that the tip 
moves equally each side of joint. 

8. When the end of the joint is reached and welded, lift 
the torch quickly in order to prevent making a hole at the end of 
the joint. 

9. Pick up the welded L with the pliers and examine the 
inner corner for penetration. Note the appearance of the corner 
when viewed from the end. 

10. Lay the welded L aside and set up two more 16-gauge 
plates and repeat the operation as many times as required to pro¬ 
duce a satisfactory job. 

Common Defects of Corner Welding 

1. Uneven fusion and poor penetration. Caused by ir¬ 
regular motion of the torch. 

2. Holes in joint. Caused by holding torch still too long 
in one place. 

3. Hole in joint at end. Caused by not lifting the torch 
quickly when the end of the joint was reached and welding com¬ 
pleted. 

4. Weld thinner than the plates when viewed from the 
end. Caused by not using adding material. This defect is un¬ 
avoidable unless adding material is supplied. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

(( 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

U 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

h-Vi $ 

3 

6 

8.1 

« 

9.3 

(6 

4 


4 

8 

12.5 

u 

14.3 

u 

5 

M—h 

5 

10 

17.8 

a 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

a 

7 

A -K 

6 

14 

33.2 

u 

37.9 

u 

8 

l A- 5 A 

6 

16 

42.0 

u 

47.9 

u 

9 


6 

18 

58.0 

u 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

ll 

89.0 

a 

101.2 

u 

12 

\ Heavy / 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING I/S OF 14-GAUGE 
STEEL PLATES WITH ADDING 

MATERIAL 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


f'orm 404 




Welding L’s of 14-Gauge Steel Plates with Adding 

Material 

• 

Each station equipment in the work-room is the same as 
specified for “Butt Welding 14-Gauge Plates with Adding Ma¬ 
terial”, 14-gauge plates and 1/16 inch welding wire in 18-inch 
lengths being supplied. 

1. Set up two 14-gauge plates on the firebricks so as to 
form an L, the corner being up. 



CORNER WELDING STEEL PLATES WITH ADDING MATERIAL 

2. Tack at each end, using the welding wire to fill. 

3. Start welding at the left hand end using the welding 
wire to fill the corner. 

4. Manipulate the torch back and forth across the joint; 
fuse the edges thoroughly and form a puddle. 





























5. Add sufficient welding material to fill the joint and make 
the thickness in the corner slightly more than the thickness of the 
plate. 

G. Continue to weld, moving to the right as fast as the 
puddle advances. Supply adding material as uniformly as possible. 

7. Make sure that fusion penetrates and a perfect weld is 
secured clear through. 

8. Avoid melting the welding wire with the flame letting 
the molten drops pile and form “cold shuts” in the joint. Make 
the puddle melt the welding wire. 

9. Pick up the welded L with the pliers and examine under¬ 
neath for penetration. Note if the weld is uniform throughout. 

10. Break the welded' pieces apart and study the weld. Note 
the defects. 

11. Remember that 14-gauge plates are thicker than the 16- 
gauge and more heat will be required to fuse the joint clear 
through and secure penetration of the weld. 

12. Repeat the exercise and test by breaking apart. Learn 
to criticise your own work. 

Common Defects of L’s Welding with Adding 

Material 

1. Imperfect penetration. Caused by rushing the work and 
not waiting until the puddle is formed and fusion has penetrated 
clear through. 

2. Welds sound on the near side but. imperfect at the far 
side. Caused by not working the torch across the joint equally 
on each side. 

3. Imperfect welds, containing lapped metal and cold shuts. 
Caused by melting the welding rod with the torch flame. The 
puddle must always melt the welding wire and feed itself; only by 
working in this way can the welder be sure that perfect fusion 
is being secured at all times. 

4. Irregularity of the weld in thickness. Caused by adding 
more welding wire at one place than another. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

iLight/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

u 

3*7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

« 

5.5 

a 

3 

■h~A 

3 

6 

8.1 

a 

9.3 

u 

4 

y%-% 

4 

8 

12.5 

« 

14.3 

a 

5 

l A-f* 

5 

10 

17.8 

u 

21.3 

a 

6 


6 

12 

25.0 

a 

28.5 

« 

7 

fs-'A 

6 

14 

33.2 

a 

37.9 

a 

8 

A-Vs 

6 

16 

42.0 

a 

47.9 

a 

9 


6 

18 

58.0 

u 

65.9 

a 

10 

%-up 

6 

20 

82.5 

a 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

a 

12 

\ Heavy/ 

8 

24 

114.5 

« 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILUE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING T’S OF 14-GAUGE 
STEEL PLATES, WITH ADDING 

MATERIAL 


DAVIS-BOURNONVILLE INSTITUTE 

JEI5SEY CITY, N. J. 


Form 405 




Welding T’s of 1 4-Gauge Steel Plates with Adding 

Material 

The station equipment in the work-room should be the same 
as provided for the exercise “Welding 14-Gauge Steel Plates, with 
Adding Material.” The No. 3 tip should be in the torch. This 
exercise differs from the exercises in corner welds in that the 
plates are set up and' welded to form a T instead of on L; one 
plate is set in the middle of the other, and at right angles to it. 



T WELDING STEEL PLATES WITH ADDING MATERIAL 


1. Set up two 14-gauge plates on the firebricks as shown 
in Fig. 1. Hold the upper plate vertical while tacking by resting 
a third plate on it to prevent falling over. 

2. Tack the ends of the joint using 1/16 inch welding 

wire. 

3. When tacking is finished, remove with the pliers and lay 
on two firebricks as shown in Fig. 2. 

4. Start welding at the left and proceed towards the right 

























































giving the torch a slightly semi-circular motion instead of a zig¬ 
zag. 

5. Remember that more heat is required here than when 
butt welding two 14-gauge plates as there is more metal to be 
heated at the joint. 

6. Be careful to get perfect fusion and a puddle of molten 
metal before advancing the torch along the joint. 

7. Use the welding wire sparingly. Try to make the weld 
with as little adding material as possible. Avoid large fillets. 

8. When the weld is finished to the end pick up the T with 
the pliers and examine for penetration. 

9. Turn the T over and weld' the other side in the same 
manner using as little welding wire as possible. Clean off tht 
oxide scale thoroughly. Give the torch a slightly semi-circular 
zig-zag motion and make a “ripple" weld. 

10. Break and examine. Note defects and try again. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

Wight/ 

1 

2 

1.0 

U 

1.3 

a 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

] 6 32 

2 

4 

4.8 

a 

5.5 

u 

3 


3 

6 

8.1 

a 

9.3 

u 

4 

/16 

4 

8 

12.5 

a 

14.3 

a 

5 

h-ts 

5 

10 

17.8 

a 

21.3 

u 

6 

k-% 

6 

12 

25.0 

« 

28.5 

a 

7 

-k-'A 

6 

14 

33.2 

u 

37.9 

u 

8 

V2-V& 

6 

16 

42.0 

u 

47.9 

a 

9 

A-% 

6 

18 

58.0 

u 

65.9 

u 

10 

M-up 

6 

20 

82.5 

a 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 10-GAUGE 
STEEL PLATES, WITH ADDING 

MATERIAL 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 406 




Butt Welding 1 0-Gauge Steel Plates, with Adding 

Material 

This exercise is a repetition of the exercise “Butt Welding 
I t-Gauge Plates with Adding Material", but on 10-gauge steel 
plates. The thicker material requires more heat and expands 
more during welding than the thinner gauge. This makes it 
necessary to provide for expansion by setting the plates slightly 
apart. The stations should be supplied with 10-gauge plates and 
Ys inch welding-wire. The No. 3 tip should be placed in the 
torch. 



BUTT WELDING STEEL PLATES, WITH ADDING MATERIAL 


1. Adjust the firebricks as directed in the exercise “Adjust¬ 
ing the Flame and' Handling the Torch", letting the plates bridge 
the space between and about pi inch at each end rest on the brick. 

2. Lay two 10-gauge steel plates on the firebrick parallel 
and about 1/1G inch apart. 

3. Tack at both ends using the welding wire to supply fill¬ 
ing material. 


































4. Start the puddle and direct the flame so that each side 
receives an equal amount of heat. 

5. Weld the seam from right to left. 

6. Hold the welding wire or adding material close to the 
puddle but not in the torch flame. Apply the adding material 
only as needed but not by fits and starts. Try to use the adding 
material evenly and thus produce uniform thickness of seam. 

7. If the weld sags and threatens to drop, lift the torch 
quickly but only for a moment. This removes the pressure of the 
gases and lets the metal cool slightly and harden. 

8. Keep the puddle advancing and the torch in continuous 
zig-zag motion across the joint. (The torch should be given a 
zig-zag motion across the joint when welding plain seams but 
should have a slightly semi-circular motion when working on 
corner welds and prepared welds.) 

9. Lift the torch quickly when the end of the joint is 
reached in order to avoid blowing a hole in the weld. 

Common Defects in Butt Welding with 10-Gauge 

Steel 

The common defects to be avoided are the same as given in 
the exercise “Butt Welding 14-Gauge Plates with Adding Mate¬ 
rial”. In order to avoid these defects the welder must acquire 
skill. Skill can only be obtained by practice and carefully follow¬ 
ing instructions. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light; 

1 

2 

1.0 

« 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

ii 

3 

h~V% 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs~ z A 

4 

8 

12.5 

a 

14.3 

i 

5 


5 

10 

17.8 

u 

21.3 

a 

6 


6 

12 

25.0 

u 

28.5 

u 

/ 


6 

14 

33.2 

a 

37.9 

u 

8 

Vi~% 

6 

16 

42.0 

(6 

47.9 

u 

9 

Vz- Z A 

6 

18 

58.0 

U 

65.9 

u 

10 

A~up 

6 

20 

82.5 

U 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

1 Heavy/ 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDENG and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT, ANGLE AND T WELDING 
14-GAUGE STEEL PLATES 

(REVIEW) 


DAVIS-BOURNONVILLE INSTITUTE 

JEISSEY CITY, J. 


Form 407 




Butt, Angle and T Welding 1 4-Gauge Steel 

(Review) 

The object of this work-room exercise is to provide a review 
of the preceeding exercises. It includes butt welding, corner 
welding and T welding, requiring the use of four 14-gauge steel 
plates. The station equipment, therefore, requires a supply of 
14-gauge steel plates and 1/16 inch welding wire. 

1. Butt weld two 14-gauge steel plates with adding mate¬ 
rial. 

2. Corner weld a 14-gauge steel plate to the butt welded 
plates using adding material. 

3. T weld a 14-gauge plate to the middle of the plate be- 



REVIEW EXERCISE IN BUTT, ANGLE AND T WELDING STEEL 

tween the butt weld and the corner weld. 

4. Carefully observe the instructions given heretofore in 
regard to manipulating the torch, use of welding wire, tacking, 
etc. 

5. Inspect each weld for penetration before passing to the 

next. 

6. Break the corner weld in a vise, and note defects. 










7. Break off the T weld and compare with the L weld. 

8. Break the butt weld and compare with the others. 
Note: —Two corner welds are shown, one being at an angle 

of about 135 degrees and the other at 90 degrees. The 135 de¬ 
gree angle or corner weld does not differ greatly from an angle 
butt weld. If done with care it should be stronger than the 90 
degree corner weld. 

Questions 

1. What forms of welding does this exercise cover? 

2. To what type of joint does a T weld belong—prepared 
or unprepared? 

3. What is the torch motion across a butt weld? 

4. What is the torch motion on a T weld? 

5. Why should a welding beginner break his welds apart? 

6. What number of tip was used for this exercise? 

7. Why was a larger tip used than for the exercise “Ad¬ 
justing the Flame and Handling the Torch.” 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

a 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

) 6 32 

2 

4 

4.8 

a 

5.5 

u 

3 


3 

6 

8.1 

a 

9.3 

a 

4- 

%-% 

4 

8 

12.5 

a 

14.3 

a 

5 

l A-TE 

5 

10 

17.8 

a 

21.3 

a 

6 


6 

12 

25.0 

a 

28.5 

a 

7 

-h~ l A 

6 

14 

33.2 

a 

37.9 

« 

8 

V2-Vs 

6 

16 

42.0 

u 

47.9 

a 

9 


6 

18 

58.0 

a 

65.9 

u 

10 

H -up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavyj 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieee Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING rs OF 10-GAUGE 

STEEL 


DAVIS-BOUBNONVIELE INSTITUTE 

JERSEY CITY, N. J. 


Form 408 




Welding I’s of 1 0-Gauge Steel 

The station equipment should include a supply of 10-gauge 
steel plates and 1/8 inch welding wire. The No. 4 tip should be 
in the torch, and the gas regulators should be adjusted to four 
and eight pounds pressure, respectively. The exercise is to build 
up an I section using 10-gauge plates arranged as shown in Fig. 6. 
Five seams are to be welded, four being corner and one butt 
weld. 

1. Weld a T first, using 10-gauge plates. 



BUILDING l’s OF STEEL PLATES BY WELDING 


2. Set up for tacking. 

3. Make the corner welds working from left to right as 
directed in the exercise “Welding T’s of 14-Gauge Steel Plates 
with Adding Material”. 

4. When the two corner welds holding the plate together 
are finished, lay two 10-gauge plates on the firebricks 1/8 inch 












































































apart. More space is required here than for a plain butt weld in 
10-gauge plates. 

5. Set the welded T over the plates so that the stem end of 
the T covers the opening between the plates. 

6. Tack at four corners. 

7. Lay between the firebricks the same as before when 
welding the corners and proceed to weld the seams, working the 
torch with a semi-circular motion and proceeding from left to 
right. 

8. Turn the I over and weld the butt seams. The plates 
are set 1/8 inch apart and the opening permits the flame to pene¬ 
trate and fuse the metal beneath. 

9. Start at the left and work to the right. 

10. Fuse the metals at the edges and bottoms. 

11. Fill the joint with adding material but be very careful 
that no laps and cold shuts are formed. 

12. Pick up the welded I with the pliers, cool in water, and 
break apart in the vise. 

13. Examine for all defects and study out the reasons for 
them. 

14. Repeat the exercise, and avoid the faults found on the 
previous weld's. 

Note: —Fig. 1. shows the method of setting up two plates 
to form a T. The third plate is laid with one end on the fire¬ 
brick and the other resting on top of the vertical plate to hold it 
while tacking. When tacking is completed the T should be set 
between two firebricks, as shown in Fig. 2, for welding the corner 
in a level position. When one side is welded the T should be 
turned over and the other side welded in the same position. The 
bottom plates required to complete the I should be tacked to¬ 
gether separately as shown in Fig. 3, and assembled with the T 
as shown in Fig. 4. When tacked the I is laid between two fire¬ 
bricks as shown in Fig. 5 for welding the corner. Fig. 6 shows 
the position for welding the butt weld between the two bottom 
plates. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

< Very 1 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\LightJ 

1 

2 

1.0 

a 

1.3 

a 

1 

1 1 

32 16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

it 

5.5 

a 

3 

-h-Ys 

3 

6 

8.1 

u 

9.3 

a 

4 

Vs-% 

4 

8 

12.5 

u 

14.3 

a 

5 

H-YS 

5 

10 

17.8 

a 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

u 

7 

ii-Vi 

6 

14 

33.2 

a 

37.9 

u 

8 

Vi-Y 

6 

16 

42.0 

a 

47.9 

u 

9 


6 

18 

58.0 

it 

65.9 

u 

10 

H~up 

6 

20 

82.5 

(( 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

Heavy / 

8 

24 

114.5 

a 

130.5 

(( 


Operators frequently adjust the pressure regulators from one to two pounds 
above ths igures given in the table to allow for yaug ‘ variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 




















DAVIS-BOURNONVILUE 
OXY-ACETYLENE WELDIiNG and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

VERTICAL WELDING L’S 
OF 16-GAUGE STEEL PLATES 


■f 


DAVIS-BOURNONVIULE INSTITUTE 

JERSEY CITY, N. J. 


Form 409 





Vertical Welding L’s of 1 6-Gauge Steel Plates 

The station equipment should be the same as for the ex¬ 
ercise “Welding L’s of 16-Gauge Steel Plates”. Place the No. 2 
tip in the torch and adjust the regulators accordingly. This exer¬ 
cise differs in that the welding is made with the plates standing 
vertical instead of horizontal. 

1. Set up two 16-gauge steel plates on the firebricks to form 
an angle of 90 degrees. The corner should slightly overhang the 
firebrick. 

2. Tack at the top and bottom. 

3. Start welding at the bottom, and work upward. 



4. Hold the torch handle horizontal and with the tip point¬ 
ing upward at an angle of about 50 degrees, with the plates. 

5. Work the torch back and forth across the joint with a 
semi-circular motion. 

6. Form a puddle before adding any welding material. 

7. Care must be used to prevent puddle becoming too 
large, and sagging down. If the puddle tends to sag, whip 
the torch quickly across the weld, lifting it slightly so as to reduce 
the heat on the metal. 

































8. Continue to weld to the top. Remember that perfect 
fusion and penetration must be secured, but if carried too far the 
puddle will sag and a hole will appear in the weld. 

9. Pick up the welded L. with the pliers, cool, and test in 
the vise. 


Questions 

1. Is a welded joint made without adding material as strong 
as when made with adding material ? Why ? 

2. What size of adding material should be used on this job? 

3. Why not use a heavy gauge rod? 

4. If the metal in the puddle sags what should be done to 
prevent it falling away? 

5. What is meant by “whipping the torch” and what is 
the effect ? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light; 

1 

2 

1.0 

U 

1.3 

a 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

s|“ 

1 

oo\ 

3 

6 

8.1 

u 

9.3 

u 

4 

y %-/16 

4 

8 

12.5 

« 

14.3 

u 

5 

H-TE 

5 

10 

17.8 

« 

21.3 

(C 

6 


6 

12 

25.0 

u 

28.5 

u 

7 

TE-V2 

6 

14 

33.2 

u 

37.9 

u 

8 

l A-Vs 

6 

16 

42.0 

u 

47.9 

a 

9 


6 

18 

58.0 

(( 

65.9 

u 

10 

%-up 

6 

20 

82.5 

u 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

\ Heavyj 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviixe Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

VERTICAL WELDING L’S 
OF 14-GAUGE STEEL PLATES 
WITH ADDING MATERIAL 


* 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, IS. J. 




Vertical Welding L’s of 14-Gauge Steel Plates, 

with Adding Material 

A supply of 14-gauge steel plates and 1/16 inch welding wire 
should be provided at the station. The exercise is vertical welding 
the same as the exercise “Vertical Welding L’s of 16-Gauge 
Plates”, but requires the use of adding material. 

1. Set up two 14-gauge steel plates on a firebrick to form an 
angle of 90 degrees. The corner of the plates should slightly over¬ 
hang the firebrick. 



WELDING STEEL PLATES VERTICALLY WITH ADDING MATERIAL 


2. Tack at the top and bottom using 1/16 inch welding wire. 

3. Start welding at the bottom and work upward giving 
the torch a semi-circular motion as it is traversed back and forth 
across the joint. 

4. Hold the torch handle horizontal and so that the tip 
points upward at an angle of about 50 degrees. 















































































































5 . Form a puddle of molten steel before adding any weld¬ 
ing material. 

6. Add welding material sparingly, and take care that the 
puddle does not become too large and sag. 

7. If the puddle tends to sag, whip the torch and reduce the 
amount of heat directed against the metal in the joint. 

8. Continue to weld to the top and when the top is reached 
remove the torch quickly to prevent blowing a hole through the 
joint. 

9. When the welded L is finished, break apart in a vise and 
note defects. 

10. Repeat the exercise, and test again. 

Questions 

1. Which is thicker, 14-gauge or 16-gauge? 

2. In what respect does this exercise differ from the exer¬ 
cise “Vertical Welding L's of 16-Gauge Steel”? 

3. What size welding wire is used in this exercise? 

4. Why is welding wire or adding material used ? 

5. Where should welding start when working on a vertical 
seam ? 

6. What should the welder do when the puddle becomes too 
large and begins to sag? 

7. What precaution should be taken to prevent blowing a 
hole through the joint at the end of a weld? 

8. Which is stronger, a corner joint welded with or with¬ 
out adding material? Why? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\Lightj 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

« 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

■h~y% 

3 

6 

8.1 

a 

9.3 

u 

4 

y%-% 

4 

8 

12.5 

a 

14.3 

a 

5 

1 A~te 

5 

10 

17.8 

a 

21.3 

a 

6 

T6~% 

6 

12 

25.0 

a 

28.5 

a 

7 

&~V2 

6 

14 

33.2 

« 

37.9 

a 

8 

l A- 5 A 

6 

16 

42.0 

u 

47.9 

u 

9 

Vs-y* 

6 

18 

58.0 

u 

65.9 

u 

10 

H-up 

6 

20 

82.5 

a 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

a 

12 

'l Heavy/ 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the iigures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

SIDE SEAM BUTT WELDING 
14-GAUGE STEEL, WITH 
ADDING MATERIAL 


DAVIS-BOURNONVILLE institute 

JERSEY CITY, N. J. 




Side Seam Butt Welding 14-Gauge Steel Plates, 

with Adding Material 

The station equipment should include 14-gauge plates and 
1/1G inch welding wire. 

1. Lay two 14-gauge plates horizontally on the firebricks 
and tack at each end. 

2. Set the plates up edgewise on the firebricks supporting 
with a firebrick as shown in Fig. 2. 

3. Start to weld at the right end and work toward the left. 

4. Hold the torch handle horizontal and direct the flame 
as nearly as possible at the same angle as when welding a level 



or “down" seam. 

5. Fuse the metal and form a puddle. Use care to prevent 
the puddle becoming too large and sagging. 

6. Manipulate the torch with a zig-zag motion across the 
joint, and add welding material the same as on a level seam. 

?. On account of the position of the plates and the operator, 
the tendency is to play the torch flame more on one side than the 
other. This must be avoided. 










































8. When the puddle sags, whip the flame away for a mo¬ 
ment thus reducing the heat. 

9. Stand easily and hold the torch freely. Learn to manipu¬ 
late the torch in any position freely and without strain. 

10. When the weld is finished, cool, and break apart in a 

vise. 

11. Compare the result with your level seam welding. 

12. Repeat the exercise, and test again. Strive to improve. 

Note :—The operator can hold the torch vertically and work 
across the seam the same as in level welding if the pieces are up 
on a level with his eves. But welding side seams should be 
practiced with the torch held horizontally on account of this work 
having to be done where the torch cannot be used in the vertical 
position. 

Questions 

1. What is the chief cause of defects in side seam welds? 

2. Are side seam welds as strong as level seam welds? 

3. What should be done to prevent burning holes in 
the plates? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

( Very \ 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\Light / 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

u 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

-fa- l A 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs-H 

4 

8 

12.5 

a 

14.3 

a 

5 

M-A 

5 

10 

17.8 

a 

21.3 

u 

6 

-h-% 

6 

12 

25.0 

u 

28.5 

u 

7 

4 

6 

14 

33.2 

a 

37.9 

u 

8 

V2- 5 A 

6 

16 

42.0 

a 

47.9 

a 

9 

Vs-Va 

6 

18 

58.0 

a 

65.9 

u 

10 

Vat up 

6 

20 

82.5 

a 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

1H eavy/ 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumDtion per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

LAP WELDING 14-GAUGE 
STEEL PLATES 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 412 




Lap Welding 1 4-Gauge Steel Plates 

The station equipment is the same as used heretofore. A 
supply of 14-gauge plates and 1/8 inch welding wire should be 
on hand, and the No. 3 tip should be in the torch. The exercise 
consists of welding three plates together making what is known 
as a lap weld. Fig. 1 shows the arrangement of the plates. 
Three seams have to be welded, two being lap seams and one a butt 
seam. 

1. Lay three 14-gauge steel plates on the firebricks as 
shown in Fig. 1. The lower plates should be parallel and 1/8 



inch apart. The upper plate should cover the opening equally 
each side. 

2. Tack the corners, A, B, C and' D. Start welding at the 
left, using 1/8 inch welding wire for adding material. 

3. Give the torch a semi-circular zig-zag motion, and use 
the adding material sparingly. 

4. Heat the edge of the upper plate and the plate beneath 
as uniformly as possible. 

5. Manipulate the torch carefully, to prevent overheating of 
the upper plate. 




























G. Fuse a puddle in the corner and hold it there. Use add¬ 
ing material sparingly but constantly. Try to make a neat weld. 

7. When the weld is finished turn the plates around and 
weld the opposite side in the same manner, working from left to 
right. 

8. Turn the plates over and weld the butt seam the same 
as in the exercise “Welding T’s of 10-Gauge Steel”. 

9. Start at the left, and work toward the right. 

10. Fill the groove with adding material, but make sure that 
the edges and bottom are perfectly fused. 

11. When the weld is finished pick it up with the pliers and 
examine. Learn to find the defects. 

12. When the plates are cool, grip in a vise with the seam 
horizontal and the vise jaw level with the middle or butt weld. 

13. Break the upper plate loose with a hammer, and note 
the parts that were welded and the parts that appeared to be 
welded. 

14. Repeat the exercise and test as before. 

Common Defects of Lap Welded Joints 

1. Imperfect fusion on the laps. Caused by not heating the 
plates uniformly. 

2. Imperfect union in the butt seam—laps and cold shuts. 
Caused by imperfect manipulation of the torch, and welding the 
adding material with the torch flame. Avoid by securing perfect 
fusion and letting the puddle melt the adding material. 

Questions 

1. To what type of joint does a lap weld belong—prepared 
or unprepared? 

2. What should be the direction of welding? 

3. What motion should be given to the torch ? 

4. What is the danger of lap welding? 

5. Why is it difficult to heat the under plate and secure per¬ 
fect fusion? 

6. Where should the puddle be formed? 

7. Do the tests show penetration of the butt welded joint 
into the upper plate? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

CC 

1.3 

a 

1 

i i 

32 16 

1 

2 

3.2 

cc 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

cc 

5.5 

u 

3 

h-v% 

3 

6 

8.1 

cc 

9.3 

u 

4 

%-% 

4 

8 

12.5 

a 

14.3 

u 

5 

H-re 

5 

10 

17.8 

cc 

21.3 

u 

6 

A- 3 Ts 

6 

12 

25.0 

cc 

28.5 

Cl 

7 

T6-^ 

6 

14 

33.2 

cc 

37.9 

cc 

8 

l A- 5 A 

6 

16 

42.0 

cc 

47.9 

Cl 

9 

Vs-H 

6 

18 

58.0 

u 

65.9 

cc 

10 

%-up 

6 

20 

82.5 

u 

94.0 

« 

11 

( Extra \ 

8 

22 

89.0 

u 

101.2 

cc 

12 

\ Heavy; 

8 

24 

114.5 

u 

130.5 

cc 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 



















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

VERTICAL LAP WELDING 
12-GAUGE STEEL PLATES,WITH 
ADDING MATERIAL 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 413 




Vertical Seam Lap Welding 1 2-Gauge Steel Plates, 

with Adding Material 

The exercise is the same as the exercise “Vertical Welding 
L’s of 14-Gauge Steel Plates”, excepting that the seam stands 
vertical instead of horizontal. The stations require a supply of 



VERTICAL LAP WELDING STEEL, WITH ADDING MATERIAL 


12-gauge steel plates. 

1. Lay three 12-gauge steel plates on the firebricks and 


















































tack as directed in the exercise “Lap Welding 14-Gauge Steel 
Plates”. 

2. Stand the tacked plates vertically as shown in Fig. 2 

3. Hold the torch handle horizontal and the tip pointing 
slightly downward. 

4. Start welding at the bottom and work upward. Give 
the torch a semi-circular motion. 

5. Fuse the metal in the corner formed by the plates and 
produce a puddle, but be careful not to make the puddle too large. 

6. If the puddle sags, whip the torch. Add welding wire 
sparingly. 

7. Weld the other vertical seam in the same manner start¬ 
ing at the bottom and working toward the top. 

8. Turn the plates around and weld the butt seam working 
from the top toward the bottom. Give the torch a semi-circular 
motion and be sure that the plates are fused clear to the bottom 
of the joint. 

9. Control the puddle and if it tends to sag, whip the torch 
and let some of the heat escape. 

10. Break the plates apart, if possible, and compare with the 
level lap welding. 

Common Defects of Vertical Lap Welded Joints 

1. The common faults are irregularity of the welds, piling 
and cold shuts. Caused by imperfect torch manipulation. 

2. Welds lumpy. Caused by position of seam and lack of 
skill. Practice only will correct the fault. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

jLight/ 

1 

2 

1.0 

(( 

1.3 

« 

1 

1 1 

32 16 

1 

t 2 

3.2 

U 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

■k-v* 

3 

6 

8.1 

a 

9.3 

u 

4 

y-% 

4 

8 

12.5 

u 

14.3 

a 

5 


5 

10 

17.8 

u 

21.3 

u 

6 

A- 3 /i 

6 

12 

25.0 

a 

28.5 

a 

7 


6 

14 

33.2 

u 

37.9 

a 

8 

y-y 8 

6 

16 

42.0 

u 

47.9 

a 

9 

y 8 -y 

6 

18 

58.0 

a 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

1 Heavy/ 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from cue to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumotion per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 



















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 


SIDE SEAM LAP WELDING 
10-GAUGE STEEL PLATES 


t 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 414 




Side Seam Lap Welding 1 0-Gauge Steel Plates 

The station equipment is the same as provided in the exer¬ 
cise “Lap Welding 14-Gauge Steel Plates”, but 10-gauge plates 
and 34-inch welding wire are provided. The No. 4 tip should be 
in the torch. The work is the same except that the plates are 
lap welded in a side seam position instead of flat or level. 

1. Lay three 10-gauge steel plates on the firebricks and 
tack as shown in Fig. 1. The bottom plates should be placed 
1/16 inch apart. 



LAP WELDING SIDE SEAMS IN STEEL PLATES 


2. Set the tacked plates up on one side as shown in Fig. 2. 

3. Hold the torch horizontal with the tip at the same angle 
to the plates as when welding a level seam. 

4. Start welding at the left using a 1/8-inch welding wire. 





































































5. Give the torch a semi-circular zig-zag motion. 

6. Heat the edge of the upper plate and the under plate 
as uniformly as possible. Form a puddle in the corner and hold 
it there. 

7. When the first weld is finished, turn the plate over and 
weld the second' lap seam. 

8. Turn the plate around and weld the butt seam. 

9. Shear the welded plates and test one of the sheared 
plates in a vise. Compare with a level seam lap weld. 

10. File the other sheared piece smooth over the welds and 
etch with etching fluid. 

11. Resolve to improve the next. 

12. Repeat the exercise. 


Acetylene and Oxygen Pressures 

Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/Very! 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

“ 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

a 

3 

h-v% 

3 

6 

8.1 

u 

9.3 

u 

4 

y-% 

4 

8 

12.3 

a 

14.3 

u 

5 

K-A 

5 

10 

17.8 

a 

21.3 

a 

6 

A-^s 

6 

12 

25.0 

u 

28.5 

u 

7 

A-H 

6 

14 

33.2 

u 

37.9 

u 

8 


6 

16 

42.0 

a 

47.9 

u 

9 

5 /6-M 

6 

18 

58.0 

u 

65.9 

u 

10 

%-up 

6 

20 

82.5 

a 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

« 

101.2 

u 

12 

\Heavy/ 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 
























DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT, VERTICAL ANGLE, T AND 
LAP WELDING, 10-GAUGE 
STEEL (Review) 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 415 




Butt, Vertical, T and Lap Welding 1 0-Gauge Steel 

(Review) 

The station equipment requires a supply of 10-gauge steel 
plates and %-inch adding material in 18-inch lengths. The exer¬ 
cise is a review of butt, vertical, angle, T and lap welding in one 
assembled piece. 

1. Lay two 10-gauge steel plates on the firebricks, and butt 
weld from right to left. 

2. Set up the butt welded steel plates with a third plate to 
form an L. 



REVIEW EXERCISE IN BUTT, VERTICAL T AND LAP WELDING 


STEEL PLATES 

3. Tack at the ends and set in a vertical position and weld 
from the bottom up. 

4. Lap weld the fourth 10-gauge plate to the L, making it 
a side beam job. Work from left to right. 

5. Tack the fifth plate in the center of the horizontal welded 
lapped plate. 

6. Weld the T seam top and bottom. 

7. Break the welds apart in the vise, and note defects. 















Common Defects of Review Test Piece Welding 

1. Irregular welding and hidden faults. Caused by over- 
confidence and hurrying the job. 

2. Defects common to first beginners. 

Note: —Welders must realize that when learning any trade 
there is a period of slow progress. Avoid getting discouraged. 
Get your “second wind” by practice and then the making of 
sound welds in any position will become easy. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light! 

1 

2 

1.0 

« 

1.3 

U 

1 

sh 

I 

3r 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

■h-Vs 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs-% 

4 

8 

12.5 

a 

14.3 

a 

5 

H-T6 

5 

10 

17.8 

u 

21.3 

a 

6 

A- 3 /s 

6 

12 

25.0 

a 

28.5 

u 

7 

T6-^ 

6 

14 

33.2 

a 

37.9 

u 

8 

l A-% 

6 

16 

42.0 

a 

47.9 

a 

9 

M-K 

6 

18 

58.0 

u 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

U 

101.2 

u 

12 

) Heavy/ 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieeb Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

• . 

BUTT WELDING 
1/4 INCH BEVELED STEEL BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 416 




Butt Welding >4 -Inch Beveled Steel Bars 

The stations require a supply of ^-inch beveled steel bars, 
6 inches long and l l /[ inch wide. The No. 4 tip should be in the 
torch, and a supply of ^4-inch welding wire in 18-inch lengths 
should be provided. 

1. Lay two j^-inch bevel steel plates on the firebricks 
parallel and 1/16 inch apart. 

2. Tack at the right hand end only. 

3. Inspect after tacking to see if the opening is parallel 
and 1/16 inch apart. If not, pry the bars until the sides of the 
opening are parallel. 



BUTT WELDING PREPARED JOINT IN ^-INCH STEEL 


4. Begin welding at the left end and proceed to the right. 

5. Break down the sides of the vee and produce a large 
puddle. 

6. Use sufficient adding material to fill the vee. 

7. Let the puddle melt the adding material. Keep the 
welding wire out of the torch flame. 

8. Give the torch a semi-circular motion and cover both 
sides of the joint equally. 























9. Be careful not to hold the torch still at the bottom of 
the vee. Carelessness in this respect will result in holes diffi¬ 
cult to fill. 

10. Proceed with the welding to the end of the joint; fill 
the vee with welding material but avoid piling it up. 

11. Shear the welded' bars and test one piece in the vise. 

12. File the end of the other piece smooth over the weld, 
polish with emery cloth and etch with acid. Note the condition 
of the weld. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

a 

1 

i i 

32 16 

1 

2 

3.2 

u 

3.7 

a 

2 

1 3 

) 6 32 

2 

4 

4.8 

u 

5.5 

u 

3 

&-y 8 

3 

6 

8.1 

« 

9.3 

u 

4 

l A-% 

4 

8 

12.6 

a 

14.3 

u 

5 

y-Ts 

5 

10 

17.8 

u 

21.3 

u 

6 

A- 3 /s 

6 

12 

25.0 

a 

28.5 

a 

7 


6 

14 

33.2 

« 

37.9 

u 

8 


6 

16 

42.0 

« 

47.9 

a 

9 

V8-V4 

6 

18 

58.0 

a 

65.9 

u 

10 

H-up 

6 

20 

82.5 

u 

94.0 

u 

11 

( Extra | 

8 

22 

89.0 

a 

101.2 

u 

12 

\ Heavy/ 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 






















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 
3/8 INCH BEVELED STEEL BABS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 417 




Butt Welding H -Inch Beveled Steel Bars 

A supply of 34-inch beveled steel bars and 3/16-inch adding 
material should be provided at the stations. The No. 6 tip should 
be placed in the torch. The pressure regulator should be set for 
6 pounds acetylene working pressure and 12 pounds oxygen 
working pressure. It is customary to set the regulators for one 
or two pounds more than the theoretical working pressure when 
using gas from cylinders in order to provide against drop in pres¬ 
sure as the gases are used up. If working with cylinder supply 
the acetylene pressure should be at about 7 pounds and the oxygen 
pressure at about 14 pounds. 



1. Lay two %-inch beveled steel bars across the firebricks 
as directed in the exercise ‘‘Butt Welding 34-Inch Beveled Steel 
Bars”, but make the difference between the edges l 2 /g inch instead 
of 1/16 inch. 

2. Remember that the steel is thicker, and that a larger 
torch flame is being used. 





























































































3. Tack at the right hand end and make sure that the 
bars remain parallel after tacking. 

4. Start welding at the left hand and build up adding 
material until the vee is filled. 

5. Give the torch a semi-circular zig-zag motion across the 
joint and secure perfect fusion on both sides and at the bottom. 

6 . Add welding material to the puddle regularly; add but 
little more than is required to fill the vee. 

7. Defects to be avoided more and more as the welds be¬ 
come heavier are laps and cold shuts. Maintain a puddle of 
molten metal constantly and feed the puddle as previously directed. 
Break down the walls equally on each side with the flame. 

8 . Weld to the end of the joint. 

9. When the end of the joint has been reached, build the 
weld up square; whip the torch up when metal tends to sag. 

10. Pick up the welded piece with the pliers, cool and 
examine for external appearance. Note if the surface is pitted or 
shiny. 

11 . Shear the plate across the weld and break one piece 
in the vise. 

12 . Prepare the other piece for etching and etch. Compare 
the defects revealed with the corresponding defect in the broken 
part. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft! 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

u 

1.3 

« 

1 

i i 

32 16 

1 

2 

3.2 

u 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

h-v* 

3 

6 

8.1 

“ 

9.3 

a 

4 

l /i~/ i 

4 

8 

12.5 

a 

14.3 

a 

5 

%-TS 

5 

10 

17.8 

u 

21.3 

u 

6 


6 

12 

25.0 

a 

28.5 

u 

7 

A-H 

6 

14 

33.2 

u 

37.9 

a 

8 

V2~% 

6 

16 

42.0 

u 

47.9 # 

u 

9 

Vs-H 

6 

18 

58.0 

<( 

65.9 

a 

10 

%-up 

6 

20 

82.5 

a 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 




















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 



Workroom Exercise 


VERTICAL WELDING 
INCH BEVELED STEEL BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 418 




Vertical Welding /4-Inch Beveled Steel Bars 

The stations require a supply of *4-inch beveled steel bars 
and ^4-inch welding rod. The No. 4 tip should be in the torch, and 
the acetylene regulator should be set at a pressure of about four 
pounds and the oxygen regulator at about eight or nine pounds. 
The exercise is one requiring considerable care and skill to exe¬ 
cute properly. 

1 . Lay two 34-inch beveled steel bars on the firebricks so 
as to leave an opening of about 1/16 inch between the edges. 



VERTICAL WELDING PREPARED JOINT IN ^-INCII STEEL 


2 . Tack at each end. 

3. Stand the tacked plates vertically using three bricks to 
support, as shown. 

4. Begin welding at the bottom. 

5. Break down the side walls and form a level puddle. 

6 . Hold the torch at an angle so that the puddle will be 
kept hot and at the same time the side walls will receive enough 
heat to produce fusion. 







































































7. Feed the puddle with adding material, using a bent 
welding rod as shown in the illustration. 

8 . Continue welding to the top, taking care to prevent lap¬ 
ping and cold shuts; and also sagging and sloughing away of the 
joint. 

9. Shear the welded plates across the middle. File and 
polish the end of one piece and etch. 

10. Break the other piece in the vise. 

11 . Compare the etched piece and the broken piece and note 
the defects revealed. 

Note.— The vertical welding should be practiced until the 
welder becomes proficient. At first it seems much more difficult 
than level welding but* experience will give the welder confidence 
and skill that enable him to produce sound' work in that as well 
as the level seam position. 

Common Defects of Vertical Welds 

1 . Imperfect penetration and adhesion, caused by improper 
torch manipulation and not breaking down the side walls suffi¬ 
ciently to produce perfect fusion. 

2. Lapping and cold shuts due to the same cause. 

3 . Sagging of the puddle, caused by overheating the adding 
material and not manipulating the torch properly. 

4 . Sloughing away of the joint caused by overheating. The 
torch should be whipped away the moment signs of sagging are 
noticed. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/Very) 

1 

1 

0.6 

cu. ft. 

0.8 cu 

. ft. 

0 

/Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

a 

3 


3 

6 

8.1 

u 

9.3 

a 

4 

v%-% 

4 

8 

12.5 

u 

14.3 

a 

5 

%-YE 

5 

10 

17.8 

U 

V 

21.3 

a 

6 


6 

12 

25.0 

u 

28.5 

a 

7 

&-V2 

6 

14 

33.2 

u 

37.9 

a 

8 

V2- 5 A 

6 

16 

42.0 

a 

47.9 

u 

9 

Vs-H 

6 

18 

58.0 

u 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

a 

12 

1 Heavy/ 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieee Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING 3/8 INCH STEEL BARS 
FOR TENSILE TEST—1 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 419 




Welding K-Inch Steel Bars for Tensile Test—1 

The station equipment requires a supply of 24 by 2 by 6 inch 
steel bars beveled to an angle of 45 degrees at the ends, and add¬ 
ing material in %-inch rods. The No. 6 tip should be in the 
torch and the gas regulators should be adjusted to six pounds 
acetylene and twelve pounds oxygen working pressure. The ob¬ 
ject of this exercise is to determine the tensile strength of oxy- 



acetylene welded steel bars. The bars are pulled apart in a Riehle 
testing machine. 

1. Carefully adjust the working pressure to six pounds 
acetylene and twelve pounds oxygen. 

2. Shim up the bars on the firebricks out of line to allow for 
contraction. Place the beveled ends ^-inch apart. 














































3 . Tack at the left and start welding, working from left to 
right. 

4. Be very careful to obtain perfect fusion and penetration. 

5. Avoid using adding material excessively thereby causing 
lapping and cold shuts. 

6. Give the torch a semi-circular motion and make sure 
that it operates equally on each side of the joint. 

7. Complete the weld; make the corners square. 

8. Cool, and pull apart in the machine to determine tensile 
strength. 

9 . Examine for defects and note the lack of penetration and 
imperfect cohesion wherever perfect fusion was not obtained. 

Note :—The strength of a weld is expressed in percentages 
of the tensile strength of an unwelded bar. The tensile strength 
of a low carbon steel bar y inch thick and 2 inches wide is from 
40,000 to 45,000 pound's. Say the average is 44,000 pounds: 
then if a welded piece pulls apart at load of 39,600 pounds the 
strength is 39,600-^44,000=0.90 of the original, or 90 per cent. 

Questions 

1. Why should the bars be shimmed up out of line when 
welded ? 

2. What should be done to bars cut with the torch before 
starting to weld? 

3. Why should the torch be given a semi-circular zig-zag 
motion across the joint? 

4. What is the approximate tensile strength of an unwelded 
low carbon steel bar 3/% inch thick and 2 inches wide? 

5. What are the principal defects of welded test bars? 

6. What percentage of the strength of an unwelded bar may 
be obtained in a sound weld? 

7. Does bending a welded bar give an indication of the ten¬ 
sile strength? 

8. What does a bending test show besides tensile strength ? 

9 . Which is the most severe test, the pulling or bending 

test? 

10. What kind of stress is a bridge girder subjected to? 

11 . What is the chief stress in a chain supporting a load? 




% 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

« 

3.7 

U 

2 

1 3 

16 3 2 

2 

4 

4.8 

u 

5.5 

u 

3 

T2~H 

3 

6 

8.1 

U 

9.3 

u 

4 

Vs~% 

4 

8 

12.5 

a 

14.3 

u 

5 

K-& 

5 

10 

17.8 

u 

21.3 

a 

6 

A- 3 Ts 

6 

12 

25.0 

a 

28.5 

u 

7 

i 

6 

14 

33.2 

u 

37.9 

a 

8 

i A-y& 

6 

16 

42.0 

u 

47.9 

u 

9 

%- z A 

6 

18 

58.0 

u 

65.9 

u 

10 

H~ up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra ] 

8 

22 

89.0 

u 

101.2 

a 

12 

\Heavyj 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING 3/8 INCH STEEL BARS 
FOR TENSILE TEST—2 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 420 




Welding H -Inch Steel Bars for Tensile Test—2 

The station equipment is the same as provided for in the 
previous exercise “Welding ^-Inch Steel Bars for Tensile Test— 
1 ”. The same bars are used, the ragged end having been trimmed 
to an angle of 45 degrees with the Oxygraph. The object of this 
exercise is to show the operator that the only sure test of a weld 
is the tensile test. 



Note: —The welder should adjust the torch flame with great 
care and should’ keep watch of the gas regulator to see that 
the working pressure does not vary greatly. One of the most 
common causes of defective welds is varying gas pressures and 
consequent carbonizing or oxidizing flames. 












































Welds of over 100 percent strength can be made by piling 
up adding material and making the weld thicker than the original 
bar. Don’t deceive yourself by doing this. Make the weld the 
same thickness as the bar. Then the test means something. 

1. Proceed to weld as before. 

2. Pull the bars in the testing machine; note the percentage 
of strength of the weld, compared to the tensile strength of the 
solid bars. 

Note: —A fine looking weld may be very weak because of the 
lack of penetration and perfect fusion of the adding material and 
the side walls. On the other hand, a rough looking weld may 
be a strong weld. The operator should perfect his methods so 
as to be able to produce weld's having from 90 to 95 per cent, 
tensile strength and at the same time present a good appearance. 

Questions 

1. How do you know when gas is being used too rapidly 
from the acetylene cylinder? 

2. What is the effect of drawing too much gas from an 
acetylene cylinder? 

3. What is the appearance of the flame when acetone is 
being drawn over? 

4 . What is the maximum that should be drawn per hour 
from a cylinder of 225 cubic foot capacity? 

5 . How many torches, each using the No. 4 tip, can 'be 
hooked onto one 225 cubic foot capacity cylinder? Why cannot 
more be connected? 





Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

« 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

a 

3 

-h-Vs 

* 3 

6 

8.1 

a 

9.3 

u 

4 

^8~/l6 

4 

8 

12.5 

a 

14.3 

a 

5 


5 

10 

17.8 

u 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

u 

7 


6 

14 

33.2 

a 

37.9 

a 

8 

V2-V8 

6 

16 

42.0 

u 

47.9 

a 

9 

*A-K 

6 

18 

58.0 

u 

65.9 

a 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

1 Heavy / 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING 3/8 INGH STEEL BARS 
FOR TENSILE TEST—3 




DAVIS-BOURNONVTLLE INSTITUTE 

j | • \ ^ I * » »/ i » .( .. ' - . 

JERSEY CITY, N. J. 


Form 421 




Welding % -Inch Steel Bars for Tensile Test—3 

The station equipment is the same as that provided for the 
previous exercises in welding -inch steel bars for tensile tests. 
The same bars are used, having been cut off at an angle of 45 
degrees with the oxygraph. 

1 . Clean the beveled ends of the bars carefully in order to 
remove all oxide left by the cutting torch. 

2 . Shim up on the firebricks and start to weld. 



Note.— Remember the defects shown in welds pulled apart, 
and try to avoid them. 

3. Keep the welding rod in the puddle. Don’t drop metal 
from the rod or melt it with the torch flame direct. 

4. Hold the torch tip above the puddle. Never dip the 
tip into the puddle and avoid holding it too close. 

Note.— Blowholes and' oxidized metal are caused by holding 
the tip too close to the molten metal. 

5. Be very careful to keep the flame adjusted to the neutral 
characteristic. Excessive sparks show an oxidizing flame. 




























Common Defects of Steel Welds 

1. Lack of penetration, and incomplete fusion at the bottom 
of the vee. 

2. Lapping and cold shuts, caused by improper torch 
handling and holding of welding rod. 

3. Burned metal, due to improper flame adjustment and 
holding the flame too long in one place without proper motion. 

4. Irregular work—thick and thin and rough. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

• 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light; 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

h-v% 

3 

6 

8.1 

“ 

9.3 

a 

4 


4 

8 

12.5 

“ 

14.3 

a 

5 


5 

10 

17.8 

a 

21.3 

u 

6 


6 

12 

25.0 

« 

28.5 

u 

7 


6 

14 

33.2 

a 

37.9 

u 

8 

l A- 5 A 

6 

16 

42.0 

u 

47.9 

a 

9 

5 A-% 

6 

18 

58.0 

« 

65.9 

u 

10 

%-up 

6 

20 

82.5 

a 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 























DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 


WELDING 3/8 INCH STEEL BARS 
FOR TENSILE TEST—4 


DAVIS - BOURNON VILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 422 






Welding Y% -Inch Steel Bars for Tensile Test—4 

This exercise is the same as the preceding exercises in 
welding inch steel bars for tensile tests. The same materials 
should be provided as before. 

1 . Weld the bars with the aim of making a 90 to 95 per cent 
weld. 

2. Weld with the aim also of making a smooth, even job 



Fig. 1 

LOW SECTION 



Fig. 3 

Copyright, 1919, by 

Davis-BournoaviUe Co. Davis Bournonvllle Institute 


CHARACTERISTIC DEFECTS IN WELDED STEEL BARS SHOWN BY 

TENSILE TEST 


with square corners. 

3. Pull the welded bar apart in the testing machine and 
record result. 



































Common Defects of Welded Test Bars 

1. Lack of alignment and consequent weakness due to 
straightening out in testing machine. 

2 . Burned metal due to overheating and improper flame 
adjustment. 

3. Blowholes due to occluded gases. 

4. Uneven joint, too full in places and not full in others. 

5. Fig. 1 shows the result of imperfect fusion of the side- 
walls and poor penetration. 

6 . Fig. 2 shows a low spot in the weld metal. 

7. Burned metal is indicated in Fig. 3. The presence of 
blue metal shows oxides and' weakness. 

Note.— The tensile tests should be supplemented with 
bending tests in order to determine the flexibility of the weld. 
If the weld metal is brittle the bending test will disclose the 
weakness much more effectually than a tensile test alone. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 • 

\Light) 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

1 

2 

3.2 

a 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

a 

3 

h-Vz 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs- Z A 

4 

8 

12.5 

a 

14.3 

a 

5 


5 

10 

17.8 

u 

21.3 

a 

6 

-h-% 

6 

12 

25.0 

u 

28.5 

a 

7 

i \- l A 

6 

14 

33.2 

u 

37.9 

u 

8 

V 2 -Vs 

6 

16 

42.0 

a 

47.9 

a 

9 

%- z A 

6 

18 

58.0 

u 

65.9 

« 

10 

% Ar up 

6 

20 

82.5 

a 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

1 Heavvj' 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 
















DAVIS-BOURNONVILLE 
OXY-AGETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

VERTICAL WELDING 10-GAUGE 
STEEL TO 1/4 INCH STEEL BAR 
TO FORM A T. (Review) 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 




Vertical Welding 10-Gauge Steel to '4-Inch Steel 

Bars to Form a T. (Review) 

The station equipment requires a supply of 10-gauge steel 
plates and 34 inch steel bars. The exercise is to set up a steel 
bar and a 10-gauge plate to form a T, and to weld in a vertical 
position. Welding thick and thin plates is advanced work and 
care must be taken to avoid overheating the thin plate. 

1. Tack a 34 inch steel bar and a 10-gauge steel plate to¬ 
gether to form a T, making the 34-inch bar the cross bar on top 
of the T. 



VERTICAL WELDING THICK AND THIN STEEL 


2. Stand the tacked parts on the firebrick so the seam is 
vertical. 

3. Start to weld at the bottom, giving the torch a semi’ 
circular zig-zag motion and using adding material. 

4. Remember that the 34 inch bar is much heavier than 


















































the 10-gauge steel plate, and more heat is required to fuse the 
metal in the thicker bar than the thin one. 

5. Exercise great care to avoid overheating the 10-gauge 

plate. 

6. Hold the torch so that the flame is directed more on 
the 54 inch steel than on the 10-gauge plate. 

7. Should the 10-gauge plate become too hot whip the 
torch off it and direct the flame against the heavier steel. 

8. Maintain the puddle and feed it with the adding ma¬ 
terial. 

9. Having finished one seam to the top, weld the other side 
in the same manner. 

10. Having finished welding, break apart in the vise and 
note defects. 

Common Defects of Thick and Thin Welding 

1. Metal overheated in the thin plate. 

2. Holes melted through the thin plate. 

3. Lack of penetration and imperfect union with thick plate. 

4. Generally irregular and spotted work. 

Note.— The welder should play the torch so that the greater 
part of the heat is directed on the thicker metal, letting the heat 
transfer from it to the thin metal in much the same manner as 
heat is transferred from the puddle to the welding rod. 






> 

) 

> 

) > 
) ) 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\Light/ 

1 

2 

1.0 

« 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 

h-Vx \ 

3 

6 

8.1 

« 

9.3 

u 

4 


4 

8 

12.6 

u 

14.3 

u 

5 

M-h 

5 

10 

17.8 

u 

21.3 

a 

6 

h-Vs 

6 

12 

25.0 

a 

28.5 

a 

*7 

/ 

h-V* 

6 

14 

33.2 

u 

37.9 

u 

8 

M-K 

6 

16 

42.0 

u 

47.9 

a 

9 

H-H 

6 

18 

58.0 

a 

65.9 

a 

10 

H-up 

6 

20 

82.5 

a 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

a 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 




















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

1 


BUTT WELDING 1/4 INCH 
BEVELED CAST IRON BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. ,J. 


Form 424 




Butt Welding % -Inch Beveled Cast Iron Bars 

The stations require a supply of l 2 3 /\. inch cast iron bars 
beveled on the sides at an angle of 45 degrees. These bars 
should be cast 1*4 inch wide and 6 inches long. Supplies of Y\ 
inch approved case iron adding material and cast iron welding 
flux are also required. The No. 5 tip should be in the torch. 
The acetylene regulator should be adjusted for a working pres¬ 
sure of 5 pounds or slightly more and the oxygen regulator for 
a pressure of 10 to 12 pounds. 



WELDING PREPARED JOINT IN CAST IRON WITH ADDING MATERIAL 

1. Lay two cast iron bars on the firebrick side by side and 
close together. 

2. Tack both ends of the bars and proceed to weld from 
left to right. 

3. Apply adding material, using cast iron welding sticks; 
dip the sticks into the flux frequently. 






























4. Break down the sides, secure perfect fusion and main¬ 
tain the puddle. 

5. Apply the adding material by melting it with the heat 
of the puddle—not directly with the torch flame. 

6. Keep the torch constantly in motion, giving it the semi¬ 
circular zig-zag motion. 

7. Endeavor to weld the joint from bottom to top as the 
welding proceeds. Avoid going back over the welded joint to 
correct faults. 

8. Build up a square corner at the end of the joint by 
whipping the torch and thus reducing the heat. 

9. Saw the weld lengthwise and crosswise with a hack saw 
to a depth of about 1/16 inch in order to test the weld for hard¬ 
ness, and to define the line of breaking when testing in a vise. 

10. Put the piece in a vise, and break the plates along the 
saw cuts. Note defects. 

Common Defects of Cast Iron Welds 

1. Trapped oxide, slag and blowholes, due to insufficient 
use of scaling powder. 

2. Trapped oxide, due to not stirring the puddle sufficiently 
with welding stick. 

3. Too large an area of weld. The welder must exercise 
care in breaking down the sides of the vee that more metal is not 
fused than is necessary for penetration. 

Note.— The oxide of cast iron melts at a higher temperature 
than the iron and must be dissolved by the use of flux. Neglect 
of the use of an approved flux will result in defective welding. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

(Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

1 

2 

3.2 

u 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

h-v% 

3 

6 

8.1 

u 

9.3 

u 

4 

Vs-% 

4 

8 

12.5 

a 

14.3 

a 

5 

H-T6 

5 

10 

17.8 

u 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

a 

7 

&- l A 

6 

14 

33.2 

u 

37.9 

a 

8 

l A- 5 A 

6 

16 

42.0 

u 

47.9 

u 

9 

5 A-H 

6 

18 

58.0 

1C 

65.9 

a 

10 

%-Up 

6 

20 

82.5 

a 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

1 Heavy/ 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for ^auge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gao consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by t the 
Davis-Bournonville Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

SIDE SEAM BUTT WELDING 
3/8 INCH BEVELED CAST 
IRON BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 425 




Side Seam Butt Welding K -Inch Beveled Cast Iron 

Bars 

This exercise is the same as the exercise in butt welding Y\ 
inch cast iron bars, except that heavier bars are used and the 
welding is a horizontal side seam job. A supply of %-mch cast 
iron welding sticks should' be furnished. 

1. Lay two ^8 inch cast iron beveled bars on the firebricks 
close together in position for tacking. 

2. Tack both ends and weld y 2 inch at the left in a hori¬ 
zontal position. 



SIDE SEAM WELDING PREPARED JOINT IN CAST IRON 


3. Set the tacked plates vertical on the firebricks and start 
to weld from left to right. 

4. Dip the welding stick in the flux box frequently. 

5. Break down the vee on the lower side until the surface 
is level sideways and slightly sloping in the direction of the joint. 

6. Fill the vee with adding material but hold the puddle so 






































































that it does not run over the side. If the puddle begins to sag 
whip the torch away from the puddle. 

7. Finish the weld to the end; square up end and cool. 

8. Saw lengthwise and crosswise with hack saw. 

9. Break in vise and note defects. 

Common Defects of Side Seam Welds 

1. Lack of penetration. 

2. Imperfect blending of adding material with parent metal 
on the upper side of weld. 

3. Breaking down of puddle and sloughing off of parent 
metal. 

4. Irregular and “spotty” work. 

5. Oxides in weld, due to infrequent use of scaling power 
and improper manipulation of torch and welding stick. 

Note. —Side seam welding is difficult but necessary and 
should be practiced until proficiency is attained. Many castings 
must be welded as they lie and the welder must be able to weld 
in all positions. 


Acetylene and Oxygen Pressures 

Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

< Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

iLight/ 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

1 

' 2 

3.2 

u 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

h-v% 

3 

6 

8.1 

u 

9.3 

u 

4 

l A-% 

4 

8 

12.5 

u 

14.3 

u 

5 

h-te 

5 

10 

17.8 

u 

21.3 

u 

6 

■h-% 

6 

12 

25.0 

u 

28.5 

u 

7 

A -h 

6 

14 

33.2 

u 

37.9 

u 

8 

V2- b A 

6 

16 

42.0 

« 

47.9 

u 

9 

Vs-% 

6 

18 

58.0 

u 

65.9 

u 

10 

M-up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 




















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

VERTICAL WELDING 3/8 INCH 
BEVELED CAST IRON BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 426 




Vertical Welding H -Inch Beveled Cast Iron Bars 

The stations require the same material provided for the exer¬ 
cise in side seam welding of cast iron bars. Vertical welding of 
cast iron requires more skill than level seam welding but the 
same rules for sound welds apply, viz: tusing the side walls and 
bottom of the vee and melting the adding material by the heat of 
the puddle. 

1. Lay two ^ inch bevel cast iron bars on the firebricks 
with edges close together, and tack at both ends. 



WELDING CAST IRON BARS VERTICALLY 


2. Stand the tacked bars vertically on firebricks in position 
for welding. 

3. Fuse down the sides of the vee and make a level puddle. 

4. Dip the welding stick into the flux box regularly. 

5. Hold the torch handle horizontal and the tip downward 
at an angle of about fifty degrees with the level. 

C. Weld toward the top, giving the torch a semicircular 















































































motion. Feed the puddle constantly but stop feeding when it 
sags. 

7. Break down the vee above the puddle as welding pro¬ 
ceeds. 

8. Finish the weld and square the corner. 

9. Saw into the weld with the hack saw and break the weld 
apart in the vise. Compare it with level and side seam cast iron 
welds. 


Common Defects of Vertical Welds 

1. Lack of penetration. 

2. Adhesions and cold shuts, due to not breaking down the 
vee above the puddle. 

3. Sagging of puddle and sloughing away of parent metal. 

4. Burned spots, due to not feeding the puddle regularly 
and moving the weld upward steadily. 

Note.— Vertical welding in cast iron is required in field work 
and the welder should practice it though difficult. If he can suc¬ 
cessfully weld side and vertical seams in cast iron he will be 
graded accordingly. Overhead seams in cast iron should not be 
tried as it is practically impossible to make sound overhead welds 
in cast iron with the torch. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

! Very \ 

1 

1 

0.6 

cu. ft. 

0.8 CU 

. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

a 

1 

i 

32 

i 

16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 

16 

3 

"32 

2 

4 

4.8 

a 

5.5 

u 

3 

3 

32 

■H 

3 

6 

8.1 

a 

9.3 

u 

4 

A- 

■% 

4 

8 

12.5 

u 

14.3 

a 

5 

x- 

5 

16 

5 

10 

17.8 

a 

21.3 

a 

6 

5 

16 

3^ 

6 

12 

25.0 

a 

28.5 

u 

/ 

7 

16 

l A 

6 

14 

33.2 

u 

37.9 

a 

8 

l A- 

% 

6 

16 

42.0 

a 

47.9 

a 

9 

Vs- 

X 

6 

18 

58.0 

a 

65.9 

u 

10 

X- 

up 

6 

20 

82.5 

u 

94.0 

u 

11 

' Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

1 Heavy/ 

8 

‘24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the ligures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieee Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUILDING CAST IRON LUGS 
WITH A CARBONITE BLOCK 


I 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 427 




Building Cast Iron Lugs with a Carbonite Block 

The exercise is building up a boss or lug y inch thick, 1 inch 
wide and 1%. inch high at the end of a ^ inch cast iron bar. 
The lug is to have a rounded end. A */ 2 -inch carbonite block is 
provided for shaping the metal and acting as a mould. The sta¬ 
tions require the same materials provided for the previous exer¬ 
cises in cast iron welding and, in addition, carbonite blocks, 
inch thick, 3 inches wide and 4 inches long. 



BUILDING LUGS OF CAST IRON WITH CARBONITE BLOCK 


1. File or carve an opening in the side of the carbonite 
block of the same size and shape as the boss to be built up. 

2. Tack and weld two ^g-inch cast iron bars together. 

3. Stand the welded cast iron bar on end, and place the 
carbonite block on the firebrick at the bottom with a steel plate 
beneath. Place the block close to the cast iron in position to form 
the boss where required. 
















































4. Start to weld at the bottom of the bar and build out into 
the opening with adding material. Fill the opening with adding 
material to a depth of ^ inch. 

5. Form a slight fillet where the boss joins the bar. 

6. Be very careful to avoid piling and cold shuts. 

7. Remove the job, cool and examine. 

8. Build another boss at the opposite end in the same man¬ 
ner. 

9. Grip in vise and break ofT lugs. Note defects. 

Common Defects of Lug Welds 

1. Imperfect union at the bottom when in welding position. 
Due to not using flux properly at the start. 

2. Shrinkage cracks, due to not keeping the parent bar pro¬ 
tected while lug is cooling. 

Note.— Lug welds are readily made with carbonite molds. 
The welder should produce a sound weld and a well-formed lug 
with little practice. Care must be taken to prevent shrinkage 
stresses in cooling. Protect the parts until cool. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

'\Light/ 

1 

2 

1.0 

U 

1.3 

« 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

SH 

i 

\H-• 

oo\ 

3 

6 

8.1 

u 

9.3 

a 

4 


4 

8 

12.5 

u 

14.3 

a 

5 

H-^e 

5 

10 

17.8 

u 

21.3 

u 

6 

A-A 

6 

12 

25.0 

cc 

28.5 

u 

7 

A-A 

6 

14 

33.2 

u 

37.9 

a 

8 

l A- 5 A 

6 

16 

42.0 

« 

47.9 

a 

9 

A-Va 

6 

18 

58.0 

a 

65.9 

a 

10 

3 4-up 

6 

20 

82.5 

u 

94.0 

a 

11 

( Extra \ 

8 

22 

89.0 

Cl 

101.2 

cc 

12 

\ Heavy j 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 1/4 INCH BEV¬ 
ELED CAST ALUMINUM BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 




Butt Welding %. -Inch Beveled Cast Aluminum Bars 

The stations should be provided with a supply of cast 
aluminum bars Y\ inch thick, 1)4 inch wide and 6 inches long; 
also 3/16 inch cast aluminum adding material, steel hook for 
breaking up the oxide film and steel spoon for smoothing. A 
12-gauge steel plate about 8 inches long and 4 inches wide must 
be provided also to support the aluminum plates while welding. 

1. Lay the 12-gauge steel plate on the firebrick, as shown 
in Fig. 1. 

2. Lay two x /\ inch aluminum bars on the steel plate, edge to 
edge. 



WELDING CAST ALUMINUM WITHOUT FLUX 


3. Join at both ends by fusing and tacking. 

4. Start welding at either end as the direction of welding 
aluminum is not important. (The illustration shows welding 
from right to left.) 

5. Aluminum radiates heat quickly and the molten metal 
quickly oxidizes over the surface. Care must be taken to obtain 
perfect fusion and a working puddle free of trapped oxide. 








































6. Thrust the aluminum adding material rod into the puddle, 
constantly giving it and the torch alternate up and down move¬ 
ments. 

7. From time to time lay down the welding rod and take 
up the oxide hook with the left hand and work out of the molten 
metal any oxide film that has not floated to the surface. 

8. As the welding proceeds use the spoon from time to time 
to smooth the surface of the joint and give it a neat appearance. 

9. Do not be afraid to work the metal with the puddling 
hook thoroughly clear down to the supporting plate beneath. 
The process of working out the oxide is helped also by using 
the welding rod in the manner described. 

10. Continue welding, using the spoon to finish the joint 
as shown in Fig. 3 before the metal hardens. 

11. Let the welded metal cool before picking up with the 
pliers. Hot aluminum is very weak and it must be handled very 
carefully to prevent breaking. 

12. When cold, test the welded joint by cutting the welded 
bars across the middle and breaking one in the vise. Smooth the 
end of the other half, polish and etch. Note penetration and 
union. 

Note.— Because of the method followed in welding aluminum 
it is always necessary to provide a support or backing beneath 
the weld. The backing material may be steel, plaster paris covered 
with asbestos paper, heavy asbestos alone for light welding or 
any other material that is firm, dry and fireproof. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

{ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Lightf 

1 

2 

1.0 

u 

1.3 

U 

1 

i 

32 

i 

16 

1 

2 

3.2 

u 

3.7 

a 

2 

1 

1 6 

3 

'32 

2 

4 

4.8 

a 

5.5 

u 

3 

3 

32 

■H 

3 

6 

8.1 

u 

9.3 

a 

4 

Vs- 

■H 

4 

8 

12.5 

a 

14.3 

u 

5 

M- 

5 

16 

5 

10 

17.8 

a 

21.3 

a 

6 

5 

16 

3 Ts 

6 

12 

25.0 

a 

28.5 

u 

7 

7 

16 

Yz 

6 

14 

33.2 

u 

37.9 

a 

8 

Vz~ 

Yz 

6 

16 

42.0 

a 

47.9 

a 

9 

Vz~ 

% 

6 

18 

58.0 

a 

65.9 

u 

10 

Vat 

up 

6 

20 

82.5 

u 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavy/ 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 




Workroom Exercise 

BUTT WELDING 3/8 INCH BEV¬ 
ELED CAST ALUMINUM BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 429 




Butt Welding H -Inch Beveled Cast Aluminum Bars 

The stations each require two small C-clamps and a supply of 
beveled cast aluminum bars % inch thick and of the same dimen¬ 
sions otherwise as used in the workroom exercise in butt welding 
14 -inch cast aluminum bars. The remainder of the station equip¬ 
ment is the same as required for that exercise. The Xo. 6 tip 
should be placed in the torch. 

1. Lay the aluminum bars on the firebrick, adjust them 
parallel and close together and clamp to a steel plate beneath for 



BUTT WELDING CAST ALUMINUM BARS 


support, as shown in Fig. 1. 

2. Tack at the left end and wxld from left to right. 

Note.— The direction of welding cast aluminum is not im¬ 
portant. It can be welded from right to left, and if welded from 
right to left the tack should be at the right end'. 

3. Use the puddling hook or film breaking tool frequently 
to break up the oxide film. 

4. Thrust the aluminum welding stick into the puddle and 
work it up and down. This helps to release the trapped oxide in 
the puddle. 































5. Continue welding to the end, being careful to build up 
a square corner when finishing the joint, in a workmanlike man¬ 
ner. Remember that the heat must be reduced’ at the end by 
whipping the torch as otherwise the metal will overheat and break 
down. 

6. Shear the welded plates across the weld, and break one 
piece apart in the vise. 

7. Note the defects, especially those caused by failure to 
eliminate the oxide. 

8. File the end of the other welded piece smooth at the 
weld, and etch. 

9. Note the defects of penetration, and compare with the 
piece broken apart in the vise. Learn to deduce how a defect 
revealed by etching affects the strength when broken apart. 

Note.— The welder can produce smoother and sounder welds 
in cast aluminum as a rule by using an approved flux than with¬ 
out it. But it is good practice to weld without flux and thus be 
able to handle the metal as conditions may require. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very 1 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light; 

1 

2 

1.0 

U 

1.3 

a 

1 

1 1 

32 16 

1 

2 

3.2 

u 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

-h-Vs 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs-H 

4 

8 

12.5 

a 

14.3 

a 

5 

H-T6 

5 

10 

17.8 

a 

21.3 

a 

6 

TS- Z /3 

6 

12 

25.0 

a 

28.5 

u 

7 

I h-K 

6 

14 

33.2 

u 

37.9 

a 

8 

V 2 -V 8 

6 

16 

42.0 

a 

47.9 

a 

9 

Vs-y* 

6 

18 

58.0 

a 

65.9 

a 

10 

%-up 

6 

20 

82.5 

(C 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavy j 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 



















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

FLANGE BUTT WELDING 
16-GAUGE SHEET ALUMINUM 
PLATES WITH FLUX 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 430 




Flange Butt Welding 16-Gauge Sheet Aluminum 

Plates with Flux 

The stations require a supply of rolled aluminum plates 16- 
gauge, 134 inch wide and 6 inches long. Flanges should be 
turned on the sides of the plate to a height of about 1/16 inch 
thus making the total of flange height and' plate thickness about 
inch. The flanged plates should be prepared for welding by 
rubbing them on a board with a little liquid aluminum flux. The 
No. 2 tip should be in the torch. 

1. Lay two flanged aluminum plates on the firebrick side by 
side, with the flanges up and touching. Start welding at the right 



WELDING SHEET ALUMINUM PREPARED WITH FLANGING 


end. 

2. Manipulate the torch back and forth across the joint in a 
zig-zag. 

3. Be very careful not to overheat the metal. Whip the 
torch upward whenever the metal gives signs of breaking down. 

4. Weld as rapidly as possible; as soon as the metal in the 
flanges begins to fuse, move the torch back and forth without 
delay. 

5. When the weld is completed, allow to cool and examine; 
it will be found thicker than the adjacent parts. 

Note. —A flanged welded aluminum sheet is generally 




















smoothed with a planishing hammer, and the thickness may be 
reduced by hammering to approximately the same as the sheet. 
When hammered down the plate will be slightly widened. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

(Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

1 

2 

3.2 

u 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

h-v% 

3 

6 

8.1 

a 

9.3 

a 

4 

l A~A 

4 

8 

12.5 

a 

14.3 

a 

5 

A~te 

5 

10 

17.8 

a 

21.3 

u 

6 

h-Vs 

6 

12 

25.0 

a 

28.5 

a 

7 

i 

6 

14 

33.2 

u 

37.9 

u 

8 


6 

16 

42.0 

a 

47.9 

a 

9 

A-A 

6 

18 

58.0 

u 

65.9 

« 

10 

A-up 

6 

20 

82.5 

u 

94.0 

a 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavyj 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieee Company 






















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 


BUILDING ALUMINUM BOSSES 
AND LUGS WITH CARBONITE 
BLOCKS (Review) 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, K. J. 


Form 431 




Building Aluminum Bosses and Lugs with Carbonite 

Blocks (Review) 

The exercise is forming bosses with aluminum adding ma¬ 
terial on % inch cast aluminum bars with the aid of a carbonite 
block recessed to form the desired shape. The stations require 
the same materials as were provided for the exercise in welding 
cast aluminum bars, and carbonite blocks the same as provided 
for boss forming in cast iron. 


CARBONITE BLOCK 



^ Fig. 3 

Copyright. 1010, ty 

Davis-Boumouviile Co. Davis Bournonville Institute 


BUILDING ALUMINUM BOSSES AND LUGS WITH CARBONITE BLOCKS 

( REVIEW ) 

1. Lay a ^ inch welded aluminum bar on a steel plate sup¬ 
ported by two firebricks. 

2. Bore a hole in a carbonite block of the required diameter 
of the round boss, say 1 inch. 




























































3. Carve an opening- in the side of another carbonite block 
to shape the lug. Make the radius of the curved part inch. 

4. Place the carbonite block with the hole in the center of 
the aluminum bar on the firebricks. 

5. Fuse the aluminum and start building up with adding 
material. 

6. Use the puddling hook to clear out the oxide film. 

7. Build up the boss to the required height and make the 
top level. 

8. Remove the carbonite block carefully. 

9. Permit the metal to cool before removing for examina¬ 
tion. Never disturb aluminum until the metal has cooled down 
to 400 or 500 degrees F. 

10. Stand the bar on end as shown in Fig. 2 with a steel 
plate beneath the carbonite block having the lug opening carved in 
the side. 

11. Build up the lug in the same manner as before, taking 
care to get perfect union at the extreme lower corner of the 
vertical bar. 

12. Build another lug as shown in Fig. 3 with the bar lying 
level. 

13. Break off the lugs and note defects. 

Note.— The hole in the carbonite block used for the center 
boss should be beveled on the lower side so as to form a slight 
fillet where the boss joins the parent metal. 

Common Defects of Boss Building 

1. Imperfect union, due to oxide and insufficient heat at the 
start. 

2. Shrinkage stresses, due to lack of protection while 
cooling. 




Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

(Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

u 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

*- Vs 

3 

6 

8.1 

u 

9.3 

a 

4 

Vs-H 

4 

8 

12.5 

u 

14.3 

a 

5 

K-A 

5 

10 

17.8 

a 

21.3 

a 

6 

-h-Vs 

6 

12 

25.0 

u 

28.5 

u 

7 

A -X 

6 

14 

33.2 

a 

37.9 

u 

8 

} 4- 5 A 

6 

16 

42.0 

u 

47.9 

a 

9 

Vs-H 

6 

18 

58.0 

u 

65.9 

u 

10 

z Ar up 

6 

20 

82.5 

u 

94.0 

a 

11 

r Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavy/ 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumotion per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 
















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BUTT WELDING 3/8 INCH 
BEVELED CAST BRONZE BARS, 

AND TESTING 


DAVIS-BOURNONVILLE INSTITUTE 

JEI5SEY CITY, N. J. 


Form 432 




Butt Welding K -Inch Beveled Cast Bronze Bars, 

and Testing 

The stations require a carbonite block, a supply of 24 inch 
beveled cast bronze bars and *4 inch bronze adding material; 
also some tested and approved bronze welding flux. The No. 6 
tip should be in the torch. 

1. Lay two 24-inch beveled cast bronze bars on the fire¬ 
brick and adjust them level and with the edges touching. 

2. Lay a carbonite block against the end of the bars so as 
to form a dam for the molten metal when starting to weld. 



WELDING PREPARED BRONZE BARS 


3. Turn on the gases and adjust for a slightly carbonizing 
flame instead of the usual neutral flame. 

4. Tack at the left and work toward the right. 

Note.— Direction of welding cast bronze is not important. 
If more convenient to tack at the right and weld toward the left, 
do so. 

5. Be very careful to avoid overheating. Raise the torch 
if the metal flows too freely. Overheating is indicated by the 





































molten metal becoming very fluid and dense white fumes rising. 

6. Avoid breathing the fumes arising from the molten 
metal as they are poisonous and detrimental to health. 

7. Maintain the puddle by adding welding material with 
the bronze welding stick and keep the puddle sufficiently hot to 
melt the adding material, but not too hot. 

8. Continue welding as rapidly as possible until the joint is 
finished. 

9. Build up the joint vertically at the end, and finish with 
a square corner by manipulating the torch so as to freeze the 
metal when it reaches the desired shape. 

10. Shear the welded bar across the weld. 

11. Break one of the sheared plates in the vise and note the 
welding penetration. 

12. File and polish the end of the other piece at the weld 
and test with etching fluid. 

Common Defects of Bronze Welds 

1. Uneven work and poor finish at the end. Holes in welds. 
Brittleness. 

2. Lack of penetration and perfect union. 

3. Segregation and other evidences of overheating. When 
white fumes rise from the metal it is too hot and the warning 
must never be neglected. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

1 

2 

3.2 

U 

3.7 

a 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

u 

3 

h-V* 

3 

6 

8.1 

“ 

9.3 

a 

4 

%-% 

4 

8 

12.5 

« 

14.3 

a 

5 

M-A 

5 

10 

17.8 

a 

21.3 

a 

6 

A- 3 /i 

6 

12 

25.0 

a 

28.5 

u 

7 

A-H 

6 

14 

33.2 

a 

37.9 

u 

8 

l A-% 

6 

16 

42.0 

(c 

47.9 

u 

9 

%- z A 

6 

18 

58.0 

u 

65.9 

u 

10 

%-up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\Heavy/ 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 



















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BRAZING 1/4 INCH COPPER 

BARS 


DAVIS-BOURNONVIELE INSTITUTE 

JERSEY CITY, N. J. 


Form 433 




Brazing >4 -Inch Copper Bars 

The stations require a supply of copper bars, 6 inches long, 
1 inch wide and 34 inch thick. Also, some 34 inch bronze welding 
rods and approved bronze flux. Use the No. 4 tip in the torch 
and adjust the regulators as for welding and for the neutral 
flame. 

1. Clean the edges to be brazed. 

2. Lay parallel on firebrick close together. 

3. Heat the copper bars all over to a cherry red. 

4. Apply flux at the joint, and start with the brazing wire 
at the left following up the joint until it is built full. 



BRAZING COPPER BARS 


Note. —Avoid holding the torch tip close to the metal. The 
temperature required for brazing is much less than for welding. 

5. Cool the brazed bars and note if the spelter has pene¬ 
trated evenly throughout the length of the joint. 

6. Break apart in the vise, and note defects. 

7. Repeat the brazing until a perfect job is secured. 

Note.—A well brazed joint in copper should tear away the 

solid copper in places when broken apart. 














Defects of Copper Brazing 

1. Unevenness, due to unclean surfaces and faulty flux 
distribution. 

2. Weakness when broken; shown by the brazing splitting 
away clean from the copper. 

3. Blowholes, due to slag or dirt getting into joint or poor 

flux. 

4. Pitted surfaces of the bars, due to overheating. 

Note. —Copper is easily brazed if the surfaces in contact are 
clean and fit closely. The cleaner the joint and the closer the fit 
the better the job. Defective brazing results from imperfectly 
cleaned and fitted joints and insufficient heat. But little flux is 
required if the mechanical conditions are correct. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light; 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

u 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

a 

5.5 

u 

3 


3 

6 

8.1 

u 

9.3 

u 

4 

Vs-% 

4 

8 

12.5 

a 

14.3 

u 

5 

H-TS 

5 

10 

17.8 

u 

21.3 

a 

6 

-h-v* 

6 

12 

25.0 

u 

28.5 

u 

7 

ts~ 1 A 

6 

14 

33.2 

u 

37.9 

u 

8 

a- 5 a 

6 

16 

42.0 

a 

47.9 

a 

9 

5 a-h 

6 

18 

58.0 

u 

65.9 

u 

10 

y-up 

6 

20 

82.5 

a 

94.0 

u 

11 

( Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

\ Heavy/ 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviblb Company 

















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BRAZING 3/8 INCH 
BROKEN MALLEABLE BARS 


DAVIS-ROURNONVILLE INSTITUTE 

JKliSEY CITY, N. J. 


Form 434 




Brazing K -Inch Broken Malleable Bars 

The stations should be provided with a supply of malleable 
bars inch thick and 1 % inch wide and 6 inches long, that have 
been broken across the mildle. The exercise is to braze the broken 
ends together. Use the No. 5 tip in the torch. 

1. Lay the fragments of the broken bar on the firebrick in 
line and close together. 

2 . Preheat with the welding torch until a low red. 

. 3. Apply approved flux to the joint. 

4. Start brazing at the left and proceed to the right, using 



BRAZING MALLEABLE IRON 


an approved bronze brazing or welding rod. 

5. When the brazing is complete, cool the bar and break 
apart in the vise. 

Note. —Place the bar in the vise with the brazed joint just 
above the edges of the vise jaws. 

6. Repeat the exercise until the brazed bar breaks at some 
other point than in the weld’. 













































Note. —Malleable cast iron is unsuitable for fusion welding. 
A well brazed joint in a broken malleable iron casting, is stronger 
than the solid metal. Hence, braze malleable cast iron. Care must 
be exercised to avoid overheating. Remember that the tempera¬ 
ture required for brazing is lower than for welding. Hold the 
torch well away from the joint and watch carefully to see when the 
brazing wire starts flowing. When hot enough to cause the braz¬ 
ing material to flow freely, avoid adding more heat than is required 
to finish the section. 




Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

1 1 

32 16 

. 1 

2 

3.2 

a 

3.7 

a 

2 

1 3 

J 6 32 

2 

4 

4.8 

a 

5.5 

u 

3 

A-X 

3 

6 

8.1 

“ 

9.3 

a 

4 


4 

8 

12.8 


14.3 

a 

5 

M—h 

5 

10 

17.8 

a 

21.3 

u 

6 

h-Vs 

6 

12 

25.0 

a 

28.5 

u 

/ 

A-X 

6 

14 

33.2 

u 

37.9 

a 

8 

Vi-% 

6 

16 

42.0 

a 

47.9 

u 

9 

y-y 

6 

18 

58.0 

a 

65.9 

u 

10 

y-up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

u 

12 

\Heavyj 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the: 
Davis-Bournonviele Company 





















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

BRAZING 3/8 INCH STEEL 

BARS 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 435 




Brazing % -Inch Steel Bars 

The stations require a supply of steel bars with square edges 
6 inches long, 1% inch wide and y inch thick. The exercise is 
to braze the edges together with bronze welding rods or adding 
material. Use the No. 5 tip in the torch. 

1. Lay two y inch steel bars on the firebricks side by side 
and close together. 

2. Heat the bars along the seam until red hot. 

3. Apply an approved' brazing flux to the joint. 

4. Apply bronze adding material at the left, working to the 
right. 



5. Keep the temperature of the steel sufficiently high to melt 
the bronze adding material without putting it under the torch 
flame. 

Note.— The rule in brazing is to make the metal hot enough 
to melt the brazing wire. 





























6. Cool the brazed plates and break apart in the vise. 

7. Repeat until satisfactory brazing is obtained. 

Note.— Steel is sometimes brazed in preference to welding 
because it can be done with a lower heat. Steel castings high in 
carbon often may be brazed with better results than when welded. 

Common Defects of Steel Brazing 

1. Imperfect union, due to unclean surfaces. 

2. Weakness, due to poor fitting together of surfaces brazed. 

3. Uneven brazing, caused by uneven heat. 

4. Rough and pitted surfaces, caused by overheating. 

5. Spelter flowed over the steel, caused by applying excess. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very ) 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light/ 

1 

2 

1.0 

U 

1.3 

« 

1 

i i 

32 16 

1 

2 

3.2 

a 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

u 

5.5 

a 

3 

&-V8 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs-% 

4 

8 

12.5 

u 

14.3 

u 

5 

M-A 

5 

10 

17.8 

u 

21.3 

u 

6 


6 

12 

25.0 

u 

28.5 

u 

7 


6 

14 

33.2 

u 

37.9 

a 

8 

V2- 5 A 

6 

16 

42.0 

a 

47.9 

a 

9 

5 A~% 

6 

18 

58.0 

u 

65.9 

u 

10 

H -up 

6 

20 

82.5 

a 

94.0 

u 

11 

( Extra) 

8 

22 

89.0 

u 

101.2 

u 

12 

\ Heavy/ 

8 

24 

114.5 

a 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the ligures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 


















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING MACHINERY 
STEEL AND TOOL STEEL 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Porm 436 




Welding Machinery Steel and Tool Steel 

A number of ^4-inch beveled machinery steel and tool steel 
bars should be provided at the stations; also ^4-inch adding 
material and approved flux. The No. 5 tip should be in the torch. 
The exercise is to weld a tool steel bar and a machinery steel bar 
together. 

1. Lay a tool steel and' a machinery steel bar side by side 
on the firebricks, adjusting them for expansion the same as pre¬ 
viously directed. 

Note.— The allowance is about 5/16-inch per foot. 



2. Tack at the left end beginning on the tool steel bar, using 
flux to protect the steel from oxidization. 

Note. —Remember that the art of welding dissimilar metals is 
chiefly in “tinning” the metal of lower fusing temperature with 
the metal of higher fusing temperature, and then grading the 
heat of the torch so as to secure perfect fusion between the tinned 





























part and the piece of higher fusing temperature. 

3. Having secured a tack union between the two bars, pro¬ 
ceed to weld, working from left to right. 

4. Direct the torch flame chiefly on the machinery steel bar, 
and feed welding rod' until a puddle is formed consisting mostly 
of adding material. 

5. Direct the torch against the tool steel cautiously so that 
the adding material tins the tool steel ahead of the weld. 

6. Feed the puddle and blend it with the tinned tool steel. 

7. Continue to weld, striving to produce a puddle that will 
unite the tool steel on one side and the machinery steel on the 
other without burning the tool steel or heating more than neces¬ 
sary to give it the protective coating of adding material. 

Note.— Tining the tool steel progressively ahead, of the weld 
protects the metal from oxidization and permits the union to be 
made by the heat of the puddle. The puddle blends with the 
coated steel. The white hot cone of the flame should never be 
directed squarely on the tool steel, if avoidable. 

8. Anneal by heating all over to redness and cooling in dry 
ashes or slaked lime. 

9. Finish the weld and test in the vise. 

Note.— High-speed steel and machinery steel can be welded 
in the same manner. The high-speed steel should be “tinned” with 
iron adding material, and' then joined to the machinery steel part 
as described. 

Common Defects of Tool Steel Welds 

1. Imperfect penetration and union. 

2. Burning, due to overheating. 

Note.— Tool steel melts at a considerably lower temperature 
than machinery steel, and is, therefore, easily overheated and 
burned. 

3. Hardness, due to rapid cooling and lack of annealing. 



Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\Light / 

1 

2 

1.0 

U 

1.3 

U 

1 

i i 

32 16 

1 

2 

3.2 

U 

3.7 

U 

2 

1 3 

16 3 2 

2 

4 

4.8 

u 

5.5 

a 

3 

k-y 8 

3 

6 

8.1 

“ 

9.3 

a 

4 

Vs-H 

4 

8 

12.5 

a 

14.3 

u 

5 

M—h 

5 

10 

17.8 

u 

21.3 

u 

6 

-k-Ys 

6 

12 

25.0 

u 

28.5 

u 

7 

k-'A 

6 

14 

33.2 

u 

37.9 

a 

8 


6 

16 

42.0 

(( 

47.9 

u 

9 

Y8-Y4 

6 

18 

58.0 

u 

65.9 

u 

10 

H-up 

6 

20 

82.5 

u 

94.0 

u 

11 

/ Extra\ 

8 

22 

89.0 

u 

101.2 

u 

12 

\Heavyj' 

8 

24 

114.5 

u 

130.5 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvieee Company 





















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 


WELDING BEVELED 
STEEL AND COPPER BARS 



DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 




Welding Beveled Steel and Copper Bars 

Provide a supply of machinery steel bars inch thick and 
square edge copper bars *4 inch thick at the stations, and a quan¬ 
tity of 3/16 inch bronze adding material; also a quantity of flux. 

1. Lay a steel bar and a copper bar on the firebricks, adjust- 
them 1/16 inch apart. 

2. Tack at the left by fusing the steel and adding the welding 
material until the half vee is full. 



WELDING BEVELED STEEL AND COPPER BARS 


3. Proceed to weld the joint working from left to right. 

4. Direct the torch flame against the steel as this is the most 
difficult to melt; the heat of the puddle will be sufficient to melt 
the copper and make the union. 


















































5. Avoid turning the torch flame against the copper as much 
as possible. 

6. Finish the weld, making sure that the joint is full. 

7. Shear the bar across the weld, and test one piece in the 

vise. 

8. Smooth the end of the other half of the bar, polish and' 

etch. 

9. Note defects in weld. 

Note.— Welding steel and copper is of practical importance 
in electric railway work when copper bonds are welded to steel 
rails. 

Common Defects of Steel and Copper Welds 

1. Copper pitted and containing blowholes; caused by over¬ 
heating and improper distribution of flux. 

2. Weakness, due to puddle not being hot enough to melt 
the copper and penetrate sufficiently to make a strong bond. 

Note.— A sound weld should break in the copper just beyond 
the joint. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

/ Very \ 

1 

i 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

\LightJ 

1 

2 

1.0 

« 

1.3 

U 

1 

1 1 

32 16 

1 

2 

3.2 

“ 

3.7 

U 

2 

1 3 

16 32 

2 

4 

4.8 

U 

5.5 

a 

3 

■h-Vs 

3 

6 

8.1 

u 

P-3 

u 

4 

Vs~% 

4 

8 

12.5 

u 

14.3 

a 

5 

M-A 

5 

10 

17.8 

« 

21.3 

u 

6 

A-SS 

6 

12 

25.0 

« 

28.5 

a 

7 

A-H 

6 

14 

33.2 

« 

37.9 

« 

8 

l A-% 

6 

16 

42.0 

u 

47.9 

u 

9 


6 

18 

58.0 

u 

65.9 

a 

10 

Vat up 

6 

20 

82.5 

u 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

\Heavyj' 

8 

24 

114.5 

u 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 
























DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 


ADJUSTMENT AND USE 
OF OXY-ACETYLENE TORCH 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Fo:m 438 




Adjustment and Use of Oxy-Acetylene Cutting Torch 

The welding torches at the stations are replaced by the Davis- 
Bournonville Style C cutting torch, No. 3000-A. A number of 
10-gauge steel welding plates should be provided. 

1. Place a No. 1 tip in the torch. 

2. Open the oxygen cylinder valve with the left hand hold* 
ing the torch in the right hand. 



ADJUSTMENT OF FLAME OF CUTTING TORCH 


3. Adjust the oxygen regulator to a working pressure of 
ten pounds with the needle valve open. 

4. Close the oxygen needle valve in the torch and' open the 
acetylene cylinder valve. 

5. Adjust the acetylene regulator to a working pressure of 
three pounds with the acetylene needle valve open. 





















































G. Ignite the acetylene gas. 

7. Turn on the oxygen needle valve, and adjust for a 
neutral or slightly oxidizing flame. 

8. Direct the flame against the edge of the 10-guage steel 

plate. 

9. When the metal has become white hot, pull the trigger 
in the torch and proceed to cut. 

10. Cut the plate in two, and repeat the operation. 

11. If the flame snaps out, release the trigger valve, ignite 
and preheat again if necessary. 

12. When cutting is finished release the trigger valve. 

13. Close the oxygen needle valve. 

14. Close the acetylene needle valve. 

15. Close the acetylene cylinder stop valve with the left 
hand. 

16. Open the acetylene needle valve. 

17. Release the acetylene pressure regulator handle. 

18. Close the oxygen cylinder stop valve. 

19. Open the oxygen needle valve. 

20. Release the oxygen pressure regulator handle. 

21. Close the needle valves in the torch. 

22. Hang up the torch. 

Note.— The cutting torch provides two oxygen tubes leading 
to the head, and' a trigger controlled throttle valve for turning on 
the excess oxygen supply required for cutting. Preheating to 
red-or white-hotness is required before the excess oxygen can be 
turned on. The oxygen combines with the steel only when it 
has been raised to the ignition .point, which is about 1500 .to 1600 
degrees R 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Cutting Torches 

with Style 12 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* * 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

1 

X 

3 

10 

12.2 

cu. ft. 

42 

cu. ft. 

1 

A 

3 

15 

12.2 

U 

48 

« 

1 

X 

3 

20 

12.2 

a 

55 

u 

1 

5 

16 

3 

20 

12.2 

« 

55 

u 

2 

X 

3 

10 

12.2 

a 

62 

u 

2 

X 

3 

20 

12.2 

« 

84 

u 

2 

X 

3 

30 

12.2 

a 

106 

u 

2 

1 

3 

35 

12.2 

a 

116 

u 

3 

1 

4 

30 

19.7 

u 

142 

« 

3 

IX 

4 

40 

19.7 

u 

172 

u 

3 

2 

4 

50 

19.7 

u 

202 

u 

3 

3 

4 

60 

19.7 

a 

232 

a 

4 

3 

5 

60 

30.6 

a 

316 

u 

4 

4 

5 

70 

30.6 

a 

356 

u 

4 

5 

5 

85 

30.6 

a 

416 

u 

4 

6 

5 

100 

30.6 

u 

476 

a 

5 

6 

6 

90 

30.6 

a 

600 

a 

5 

7 

6 

100 

30.6 

a 

668 

u 

5 

8 

6 

125 

30.6 

a 

838 

a 

5 

10 

8 

150 

30.6 

u 

1,008 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 








































DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

CUTTING 1/4 INCH STEEL 
PLATE WITH THE TORCH 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 439 




Cutting l /i -Inch Steel Plate with the Torch 

A *4 inch steel plate eight or ten inches long should be pro¬ 
vided at the welding pit. On this plate should be laid out a pattern 
for the operator to follow. The No. 1 tip should be in the torch, 
and the acetylene pressure should be adjusted to 3 pounds and 
the oxygen pressure to 20 pounds. 

1. Light the torch and fuse the edge of the plate. 

2. Pull the trigger valve, and' proceed to cut. 

3. Follow the pattern as closely as possible. 

4. Do not grab the torch firmly but hold it easily. 



CUTTING A DESIGN FROM A STEEL PLATE WITH THE CUTTING TORCH 

5. When cutting an arc hold the torch so that the tip can be 
swung around an imaginary pivot in the handle. 

6. Having cut out the pattern, practice starting a cut. En¬ 
deavor to start the cut quickly so as to save time and gas. 

7. Shut off the gases as directed in exercise “Adjustment 
and Use of Oxy-Acetylene Cutting Torch/’ 

Note.— It is important that the operator learn to hold the 
cutting torch easily, follow a line accurately and cut as narrow 

































a kerf as possible. This can be best accomplished, strange as it 
may seem, by giving the torch a slight zig-zag motion across the 
cut. It is practically impossible to hold an instrument firmly 
and follow a line without wavering. If the workman deliberate¬ 
ly zig-zags the torch he will find it easier to follow a line. The 
movement should be so short as to be barely perceptible. 


Defects 



1. Wide kerf. Strive to cut as narrow a path as possible in 
order to save steel and gas. 

2. Ragged edges, caused by poor quality oxygen and un¬ 
steady holding of torch. 

3. Underhanging and overhanging edges, caused by not di¬ 
recting the oxygen stream squarely downward but at an angle. 

Note.— Cutting should' be done at a pit built of brick or con¬ 
crete, or with a metal plate standing vertically between the sparks 
and operator’s legs. The sparks should be directed into a large 
metal can if no pit or other protection is available. Avoid direct¬ 
ing the sparks against anything that will take fire. If an empty 
carbide can is used be sure it is free of carbide and acetylene 


gas. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Cutting Torches 

with Style 12 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

1 

Vs 

3 

10 

12.2 

cu. ft. 

42 

cu. ft. 

1 

X 

3 

15 

12.2 

U 

48 

U 

1 

X 

3 

20 

12.2 

U 

55 

u 

1 

5 

1 •> 

3 

20 

12.2 

u 

55 

u 

2 

X 

3 

10 

12.2 

u 

62 

u 

2 

V* 

3 

20 

12.2 

a 

84 

u 

2 

X 

3 

30 

12.2 

a 

106 

u 

2 

l 

3 

35 

12.2 

a 

116 

a 

3 

l 

4 

30 

19.7 

a 

142 

u 

3 

i X 

4 

40 

19.7 

a 

172 

u 

3 

2 

4 

50 

19.7 

a 

202 

u 

3 

3 

4 

60 

19.7 

u 

232 

a 

4 

3 

5 

60 

30.6 

u 

316 

« 

4 

4 

5 

70 

30.6 

u 

356 

u 

4 

5 

5 

85 

30.6 

u 

416 

u 

4 

6 

5 

100 

30.6 

a 

476 

u 

5 

6 

6 

90 

30.6 

a 

600 

u 

5 

7 

6 

100 

30.6 

a 

668 

u 

5 

8 

6 

125 

30.6 

a 

838 

« 

5 

10 

8 

150 

30.6 

u 

1,008 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 








































DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

CUTTING 1/4 INCH STEEL 
ANGLES WITH THE TORCH 


DAVIS -BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 440 




Cutting % -Inch Steel Angles with the Torch 

This cutting exercise is identical with the exercise in cutting 
inch steel plate, and is simply provided for practice on struc¬ 
tural steel. Some scrap angle bars about p* inch thick should be 
provided at the cutting pit. 

1. Lay off the cuts required and mark with chalk. Prick 
the chalk line plainly. 

2. Light the torch and proceed to cut. 

3. Cut square across the angle bar. 

4. Cut an angle of 45 degrees across one leg of the bar. 



STEEL ANGLES AT THE CUTTING PIT LAID OUT FOR CUTTING 


5. Cut both legs of the angle bar at an angle of 45 degrees. 

6. Practice cutting other angles so that proficiency in shap¬ 
ing structural parts to fit will be acquired. 

Note. —Rust should be cleaned off before starting to cut. 
Direct the preheating flame against the metal along the layout 
lines and it will crack loose. 


















































Common Defects of Angle Cutting 

1. Inaccuracy of cut, due to not following the layout lines. 

2. Ragged and uneven cutting, caused by not holding the 
torch steady. 

Note.— Torch cutting requires steadiness of hand and prac¬ 
tice to acquire proficiency. The thicker the metal the greater the 
skill required. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Cutting Torches 

with Style 12 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

1 

Vs 

3 

10 

12.2 

cu. ft. 

42 

cu. ft. 

1 

H 

3 

15 

12.2 

U 

48 

U . 

1 

H 

3 

20 

12.2 

U 

55 

U 

1 

5 

16 

3 

20 

12.2 

U 

55 

li 

2 

M 

3 

10 

12.2 

. u 

62 

a 

2 

Vi 

3 

20 

12.2 

a 

84 

u 

2 

% 

3 

30 

12.2 

u 

106 

u 

2 

1 

3 

35 

12.2 

u 

116 

a 

3 

l 

4 

30 

19.7 

« 

142 

u 

3 

i H 

4 

40 

19.7 

a 

172 

u 

3 

2 

4 

50 

19.7 

u 

202 

a 

3 

3 

4 

60 

19.7 

u 

232 

u 

4 

3 

5 

60 

30.6 

u 

316 

a 

4 

4 

5 

70 

30.6 

u 

356 

u 

4 

5 

5 

85 

30.6 

u 

416 

u 

4 

6 

5 

100 

30.6 

a 

476 

a 

5 

6 

6 

90 

30.6 

u 

600 

u 

5 

7 

6 

100 

30.6 

u 

668 

a 

5 

8 

6 

125 

30.6 

« 

838 

u 

5 

10 

8 

150 

30.6 

u 

1,008 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonvilee Company 




l 










































DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

USE OF OXYGRAPH 
ON 3/4 INCH STEEL PLATES 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 441 







lli 

o 



to © 
'Z CQ 


USE OF OXYGRAXII ON STEEL PLATE SHOWING PATTERN LAYOUT 














































































































Use of Oxygraph on U -Inch Steel Plates 

This exercise is a demonstration of the oxygraph on ^4-inch 
steel plates to show what can be done in cutting shapes from 
steel with the machine controlled cutting torch. The instructor 
demonstrates how the oxygraph is used, and then appoints mem¬ 
bers of the class to cut out specified shapes following patterns 
drawn on paper. A triangular steel piece is to be cut. 

1. Make a drawing on heavy brown paper of a triangle 
having two sides five inches long and the third side four inches 
long. 

Note.— Drawings for oxygraph cutting must be made two 
times the size of the plate to be cut out. Hence, the drawing of 
the triangle must be made with the sides two times the length 
required on the piece. 

2. Draw in dotted lines the path of the tracing wheel. 

Note. —The tracing wheel path should be drawn 3/16 inch 

from the full lines of the design, outside in this case. 

3. Place the drawing on the oxygraph table and secure in 

place. 

4. Place a ^4-inch steel plate on the supporting ledges 
beneath the torch. 

5. Trace the outline of the drawing and note the path of 
the torch over the steel. If the steel plate is not in position so that 
the full design will be cut out adjust it until it is. 

6. Start the electric motor operating the tracing wheel and 
practice following the triangular design. 

7. Open the gas cylinder valves and adjust for a working 
pressure of three pounds on the acetylene gauge and thirty pounds 
on the oxygen gauge. 

8. Adjust the torch to the proper height above the plate 
and light with the ignitor. 

9. Preheat the edge of the plate until the igniting tempera¬ 
ture of steel is reached then turn on the cutting oxygen and 
proceed to cut. 

10. Follow the dotted line with the tracing wheel around the 
pattern until the complete circuit is made. 

Note. —The oxygraph has a machine cutting torch mounted 


on a pantagraph. The pantagraph reduces the torch movement to 
one-half the movement of the tracing wheel. Thus, slight inac¬ 
curacies or variations from the path are reduced one-half. 

11. Repeat the exercise but with the object of cutting a tri¬ 
angular hole in the plate as for a die. 

Note. —Dotted lines for the tracer wheel must be drawn on 
the pattern 3/16-inch inside the lines of the design. 

When cutting a die the dotted line for the tracer wheel must 
be drawn 3/16 inch inside the design, and when cutting out a 
punch the dotted line must be drawn outside the design. 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Cutting Torches 

with Style 12 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

1 

34 

3 

10 

12.2 

cu. ft. 

42 

cu. ft. 

1 


3 

15 

12.2 

« 

48 

U 

1 

34 

3 

20 

12.2 

a 

55 

U 

1 

5 

16 

3 

20 

12.2 

a 

55 

a 

2 

34 

3 

10 

12.2 

a 

62 

a 

2 

34 

3 

20 

12.2 

u 

84 

a 

2 

A 

3 

30 

12.2 

u 

106 

a 

2 

l 

3 

35 

12.2 

u 

116 

u 

3 

l 

4 

30 

19.7 

u 

142 

a 

3 


4 

40 

19.7 

u 

172 

a 

3 

2 

4 

50 

19.7 

a 

202 

u 

3 

3 

4 

60 

19.7 

a 

232 

a 

4 

3 

5 

60 

30.6 

a 

316 

u 

4 

4 

5 

70 

30.6 

a 

356 

a 

4 

5 

5 

85 

30.6 

a 

416 

u 

4 

6 

5 

100 

30.6 

« 

476 

u 

5 

6 

6 

90 

30.6 

u 

600 

u 

5 

7 

6 

100 

30.6 

a 

668 

u 

5 

8 

6 

125 

30.6 

a 

838 

u 

5 

10 

8 

150 

30.6 

a 

1,008 

a 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 









































DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

WELDING A CAST IRON TEST 

PIECE (Review) 


DAVIS-BOURNONVILLE INSTITUTE 

JERSEY CITY, N. J. 


Form 442 




Welding a Cast Iron Test Piece (Review) 

The exercise is designed to review cast iron welding, and it 
provides for level, side seam, carbonite block dam welding and 
boss forming without a dam. The metal is ^-inch cast iron bevel 
bars. The stations require the same materials otherwise provided 
for cast iron welding exercises. 



F| g-2 Fig. 3 

WELD A. BUILD BOSS BUILD CORNER BRACES 


Copyright, 1919, by 

Davie-Buiinionvilie Co Davis Bournonville Institute 

BUILDING A CAST IRON MACHINE PART BY WELDING 

1. Butt weld two %-inch cast iron bars in a level or “down” 
position. 

2. Weld a third bar vertically to the edge of the welded bars. 

3. Build a round boss at A, J^-inch high, without carbonite 
block. 























































4. Build up brackets at each end joining the horizontal and 
vertical members, using carbonite blocks to mold the metal. 

Note.— Great care must be taken when welding the brackets 
to prevent contraction breaking the brackets and bars apart. The 
parts must be kept at a low red all over until the bracket work 
is done. Then the piece must be covered with asbestos paper and 
allowed to cool slowly. 


Questions 

1. What tip should be placed in the torch for welding ^-inch 
cast iron ? 

2. To what pressure should the acetylene regulator be ad¬ 
justed ? 

3. What working pressure is required of the oxygen reg¬ 
ulator ? 

4. What should be done to prevent contraction stresses 
breaking the welds apart? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Welding Torches 

with Style 99 and 100 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

Oxygen* 
Consumption 
Per Hour 

00 

f Very \ 

1 

1 

0.6 

cu. ft. 

0.8 

cu. ft. 

0 

i Light/ 

1 

2 

1.0 

U 

1.3 

U 

1 

X 

32 

i 

16 

1 

2 

3.2 

a 

3.7 

a 

2 

1 

16 

3 

'32 

2 

4 

4.8 

a 

5.5 

a 

3 

3 

3 2 

-X 

3 

6 

8.1 

a 

9.3 

a 

4 

Vs- 

■% 

4 

8 

12.5 

a 

14.3 

u 

5 

x- 

5 

16 

5 

10 

17.8 

u 

21.3 

a 

6 

5 

16 


6 

12 

25.0 

u 

28.5 

a 

7 

7 

16 

l A 

6 

14 

33.2 

a 

37.9 

a 

8 

¥r 

% 

6 

16 

42.0 

u 

47.9 

u 

9 


X 

6 

18 

58.0 

a 

65.9 

u 

10 

X- 

up 

6 

20 

82.5 

a 

94.0 

u 

11 

f Extra \ 

8 

22 

89.0 

u 

101.2 

a 

12 

\ Heavy; 

8 

24 

114.5 

a 

130.5 

u 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are suoplied in cylinders. 

* Gas consumption per' hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonviele Company 



















DAVIS-BOURNONVILLE 
OXY-ACETYLENE WELDING and CUTTING 
COURSE OF INSTRUCTION 


Workroom Exercise 

CUTTING A DESIGN 
FROM 1/4 INCH STEEL (Review) 


DAVIS-BOURNONVIULE INSTITUTE 

JERSEY CITY, N. J. 


Form 443 





Cutting a Design from % -Inch Steel (Review) 

This exercise is provided as a test of skill in using the oxy- 
acetylene cutting torch on comparatively thin metal. Thin plates 
about 34-inch thick should be provided at the cutting pit and 
various designs should be marked on the plates for cutting out. 
The outlines should be prick punched plainly. The test is to cut 
the designs accurately and quickly, making the kerf as smooth 
and narrow as possible. 



REVIEW EXERCISE IN STEEL PLATE CUTTING 

Note. —The cutting torch may be used to perforate when 
starting a cut. If more convenient to start near the center do so. 
It takes a little more time to perforate a plate than to start a 
cut at the edge. Other things being equal, the operator should 
start cutting at the edge in order to save time and gas. The 
oxygraph may be used successfully for cutting out dies in tool 
steel but it will be necessary to preheat the steel before starting 
to cut. The higher the carbon content the more difficult it is to 
cut. 
































Questions 

1. What should the oxy-acetylene operator do first when 
starting to cut? 

2. In what positions should the regulator handles be when 
opening the cylinder stop valves 

3. What is the proper acetylene working pressure for cut¬ 
ting ^4-inch steel plates? 

4. What is the required oxygen pressure for cutting ^-inch 
steel. 

5. Why is it necessary to preheat the edge of a steel plate 
when starting to cut ? 

6. What is the use of the trigger valve on the cutting torch? 

7. What size tip should be used for cutting two inch steel? 

8. How long a time should be required for cutting a triangle 

ten inches long on each side from steel? 

9. Can tool steel be cut with the torch ? 

10. Is it necessary to start cutting at the edge of a plate? 


Acetylene and Oxygen Pressures 


Davis-Bournonville Style C Cutting Torches 

with Style 12 Tips 


Tip 

No. 

Thickness 
of Metal 
Inches 

Acetylene 

Pressure 

Lbs. 

Oxygen 

Pressure 

Lbs. 

Acetylene* 
Consumption 
Per Hour 

% 

Oxygen* 
Consumption 
Per Hour 

1 

Vs 

3 

10 

12.2 

cu. ft. 

42 CU. ft. 

1 

% 

3 

15 

12.2 

U 

48 “ 

1 

X 

3 

20 

12.2 

a 

55 “ 

1 

5 

16 

3 

20 

12.2 

a 

55 “ 

2 

X 

3 

10 

12.2 

a 

62 “ 

2 

X 

3 

20 

12.2 

u 

84 “ 

2 

X 

3 

30 

12.2 

a 

106 “ 

2 

1 

3 

35 

12.2 

u 

116 “ 

3 

1 

4 

30 

19.7 

a 

142 “ 

3 

IX 

4 

40 

19.7 

(C 

172 “ 

3 

2 

4 

50 

19.7 

a 

202 “ 

3 

3 

4 

60 

19.7 

a 

232 “ 

4 

3 

5 

60 

30.6 

u 

316 « 

4 

4 

5 

70 

30.6 

a 

356 “ 

4 

5 

5 

85 

30.6 

u 

416 “ 

4 

6 

5 

100 

30.6 

a 

476 « 

5 

6 

6 

90 

30.6 

u 

600 “ 

5 

7 

6 

100 

30.6 

u 

668 “ 

5 

8 

6 

125 

30.6 

« 

838 “ 

5 

10 

8 

150 

30.6 

« 

1,008 “ 


Operators frequently adjust the pressure regulators from one to two pounds 
above the figures given in the table to allow for gauge variations and drop of pressure 
when the gases are supplied in cylinders. 

* Gas consumption per hour is the maximum with torch burning continuously. 


Copyright 1919 by the 
Davis-Bournonville Company 






















































! 



\ 


library of congress 



0 003 338 423 



